Installation Manual

Generator Set
QSK23 - G3/G9 Engine with PowerCommand® 3.3 or
3.3 MLD Control

C750 D6
C750 D6 (Spec J-K)
C800 D6
C800 D6 (Spec J-K)
C825 D5
C825 D5 (Spec J-K)
C825 D5e (Begin Spec K )
C825D5E (Begin Spec K)
C900 D5
C900 D5 (Spec J-K)
C900 D5e (Begin Spec K )
C900D5E (Begin Spec K)

English
Original Instructions 10-2023 A045E599 (Issue 5)
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS.................................................................................. 1
1.1 Warning, Caution, and Note Styles Used in This Manual ................................................ 1
1.2 General Information........................................................................................................... 1
1.2.1 General Safety Precautions.................................................................................... 1
1.3 Generator Set Safety Code ............................................................................................... 4
1.3.1 Generator Set Operating Areas.............................................................................. 5
1.3.2 Moving Parts Can Cause Severe Personal Injury or Death ................................... 5
1.3.3 Positioning of Generator Set - Open Sets.............................................................. 5
1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death ............ 6
1.4.1 Locking the Generator Set Out of Service ............................................................. 6
1.4.2 AC Supply and Isolation ......................................................................................... 7
1.4.3 AC Disconnect Sources.......................................................................................... 8
1.5 Fuel and Fumes Are Flammable....................................................................................... 8
1.5.1 Spillage.................................................................................................................. 8
1.5.2 Fluid Containment ................................................................................................. 8
1.5.3 Do Not Operate in Flammable and Explosive Environments ................................. 9
1.6 Exhaust Gases Are Deadly ............................................................................................... 9
1.6.1 Exhaust Precautions.............................................................................................. 9
1.7 Earth Ground Connection................................................................................................ 10
1.8 Decommissioning and Disassembly................................................................................ 10

2. INTRODUCTION .................................................................................................................... 11
2.1 About This Manual .......................................................................................................... 11
2.1.1 Additional Installation Manual Information............................................................ 11
2.2 Schedule of Abbreviations............................................................................................... 12
2.3 Related Literature ............................................................................................................ 12
2.3.1 Further Information - Literature............................................................................. 13
2.4 After Sales Services ........................................................................................................ 13
2.4.1 Maintenance ........................................................................................................ 13
2.4.2 Warranty ............................................................................................................... 14

3. SYSTEM OVERVIEW............................................................................................................. 15
3.1 Generator Set Identification............................................................................................. 15
3.1.1 Nameplate - Open Generator Set ........................................................................ 15
3.1.2 Nameplate ............................................................................................................ 16
3.2 Generator Set Components ............................................................................................ 16
3.3 Generator Set Rating ...................................................................................................... 17
3.4 Engine ............................................................................................................................. 18
3.5 Sensors ........................................................................................................................... 18
3.6 Pyrometers - Engine Exhaust.......................................................................................... 19
3.6.1 Pyrometer Position ............................................................................................... 19
3.7 System Options ............................................................................................................... 19
3.7.1 Introduction ........................................................................................................... 19
3.7.2 Battery Charger .................................................................................................... 19
3.7.3 Fuel Tank.............................................................................................................. 19
3.7.4 Heaters ................................................................................................................. 20

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3.7.5 Relays................................................................................................................... 21
3.7.6 Motorized Circuit Breaker ..................................................................................... 21

4. INSTALLATION OVERVIEW.................................................................................................. 23
4.1 Application and Installation.............................................................................................. 23
4.2 Safety Considerations ..................................................................................................... 23
4.3 Standby Heating Devices ................................................................................................ 24
4.4 Product Modifications ...................................................................................................... 24
4.5 Derating Factors............................................................................................................. 24

5. SPECIFICATIONS .................................................................................................................. 25
5.1 Generator Set Specifications........................................................................................... 25
5.2 Engine Fuel Consumption ............................................................................................... 25

6. INSTALLING THE GENERATOR SET................................................................................... 27

6.1 Transportation ................................................................................................................. 27
6.2 Location ........................................................................................................................... 28
6.3 Moving the Generator Set ............................................................................................... 29
6.3.1 Rigging Instructions .............................................................................................. 30
6.4 Mounting.......................................................................................................................... 32
6.5 Vibration Isolator Installation and Adjustment Procedure (For IGB) ............................... 33
6.6 Access to Generator Set ................................................................................................. 34
6.7 Generator Set Long Term Storage.................................................................................. 34

7. MECHANICAL CONNECTIONS............................................................................................. 35
7.1 Fuel System..................................................................................................................... 35
7.1.1 Fuel Return Restrictions (or Pressure) Limit ........................................................ 35
7.1.2 Fuel Line Connections.......................................................................................... 36
7.1.3 Engine Fuel Connections ..................................................................................... 41
7.1.4 Supply Tank.......................................................................................................... 41
7.1.5 Fuel Inlet Pressure/Restriction Limit..................................................................... 41
7.1.6 Fuel Additives ....................................................................................................... 41
7.2 Exhaust System............................................................................................................... 42
7.3 Ventilation and Cooling ................................................................................................... 46
7.4 Vents and Ducts .............................................................................................................. 47
7.5 Dampers .......................................................................................................................... 48
7.6 Air Inlet and Outlet Openings .......................................................................................... 48

8. DC CONTROL WIRING.......................................................................................................... 53
8.1 Digital Connections.......................................................................................................... 53
8.2 Relay Connections .......................................................................................................... 54
8.3 PowerCommand 3.3 Customer Connections .................................................................. 54
8.3.1 Configurable Outputs............................................................................................ 54
8.3.2 Remote Start ........................................................................................................ 54
8.3.3 Configurable Inputs .............................................................................................. 54
8.3.4 Remote Emergency Stop ..................................................................................... 55
8.4 Ground Fault Relays ....................................................................................................... 55
8.4.1 Ground Fault Relay with Local Current Transformer ........................................... 55
8.4.2 Ground Fault Relay Installation ............................................................................ 56

9. AC ELECTRICAL CONNECTIONS ........................................................................................ 59

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9.1 Transfer Switch................................................................................................................ 60

9.2 Alternator Voltage Connections....................................................................................... 61
9.3 Load Connections............................................................................................................ 61
9.3.1 Generator Set Load Cable Installation ................................................................. 62
9.3.2 Cabling through Non-Ferrous Gland Plates ......................................................... 62
9.3.3 Cabling through Ferrous Gland Plates ................................................................. 62
9.3.4 Distribution Cables ............................................................................................... 62
9.3.5 Enclosure Light..................................................................................................... 63
9.4 Installation of s-CAN Network Cable ............................................................................... 63
9.5 Load Balancing................................................................................................................ 65
9.6 Current Transformers ...................................................................................................... 65
9.7 Coolant Heater ................................................................................................................ 65
9.7.1 Coolant Heater Connection .................................................................................. 65
9.8 Alternator Heaters ........................................................................................................... 65
9.8.1 Alternator Heater Connection ............................................................................... 65
9.9 Control Box Heater.......................................................................................................... 66
9.9.1 Control Box Heater Installation............................................................................. 66
9.10 Battery Commissioning.................................................................................................. 66
9.10.1 Safety Precautions ............................................................................................. 66
9.10.2 Pre-Commissioning Procedure........................................................................... 67
9.10.3 Charging - Commissioning ................................................................................ 67
9.10.4 Connecting the Battery to the Generator Set ..................................................... 67
9.11 Battery Charger ............................................................................................................. 67
9.11.1 Mains (Utility) Battery Charger - Wall Mounted.................................................. 67
9.12 Grounding...................................................................................................................... 68

10. PRE-START PREPARATION ............................................................................................... 71

10.1 Initial Pre-Start Checks.................................................................................................. 71
10.2 Electrical System ........................................................................................................... 72
10.3 Battery Connections ...................................................................................................... 72
10.4 Site-Specific Configuration ............................................................................................ 72
10.5 Starting .......................................................................................................................... 73

11. INSTALLATION CHECKLIST................................................................................................ 75

11.1 Checklist ........................................................................................................................ 75

12. MANUFACTURING FACILITIES........................................................................................... 79

12.1 How to Obtain Service .................................................................................................. 79

APPENDIX A. ALTERNATOR RECONNECT DRAWING........................................................... 81

A.1 0625-3100 Reconnect Drawing for HC Alternator .......................................................... 83

APPENDIX B. OUTLINE DRAWINGS......................................................................................... 85

B.1 A051A703 Outline Drawing (For IBC and CSA) ............................................................. 87
B.2 A064F343 Outline Drawing (Enclosed Genset) .............................................................. 89
B.3 A066H639 Outline Drawing (Open Genset).................................................................... 92

APPENDIX C. WIRING DIAGRAMS ........................................................................................... 95

C.1 A050R932 Wiring Diagram with PowerCommand 3.3 Control ....................................... 97
C.2 A051C423 Control Box Heater Wiring Diagram with PowerCommand 3.3 Control ..... 110
C.3 0625-3100 Wiring Diagram- Generator Reconnect ...................................................... 112

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C.4 0630-2727 Wiring Diagram- Control ............................................................................. 113

C.5 0630-3216 Wiring Diagram- Control ............................................................................. 114
C.6 0630-3217 Wiring Diagram- Schematics ...................................................................... 115
C.7 0630-2934 Wiring Diagram- Schematics ...................................................................... 116
C.8 0630-2935 Wiring Diagram- Schematics ...................................................................... 117

Copyright © 2023 Cummins Inc. iv A045E599 (Issue 5)

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

1.1 Warning, Caution, and Note Styles Used in This

Manual
The following safety styles and symbols found throughout this manual indicate potentially hazardous
conditions to the operator, service personnel, or equipment.

DANGER
Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING
Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE
Indicates information considered important, but not hazard-related (e.g., messages relating to
property damage).

1.2 General Information

This manual should form part of the documentation package supplied by Cummins with specific
generator sets. In the event that this manual has been supplied in isolation, contact your authorized
distributor.

NOTICE
It is in the operator’s interest to read and understand all warnings and cautions contained
within the documentation relevant to the generator set, its operation and daily maintenance.

1.2.1 General Safety Precautions

WARNING
Hot Pressurized Liquid
Contact with hot liquid can cause severe burns.
Do not open the pressure cap while the engine is running. Let the engine cool down before
removing the cap. Turn the cap slowly and do not open it fully until the pressure has been
relieved.

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1. IMPORTANT SAFETY INSTRUCTIONS 10-2023

WARNING
Moving Parts
Moving parts can cause severe personal injury.
Use extreme caution around moving parts. All guards must be properly fastened to prevent
unintended contact.

WARNING
Toxic Hazard
Used engine oils have been identified by some state and federal agencies to cause cancer or
reproductive toxicity.
Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil.
Wear protective gloves and face guard.

WARNING
Electrical Generating Equipment
Incorrect operation can cause severe personal injury or death.
Do not operate equipment when fatigued, or after consuming any alcohol or drug.

WARNING
Toxic Gases
Substances in exhaust gases have been identified by some state and federal agencies to
cause cancer or reproductive toxicity.
Do not breathe in or come into contact with exhaust gases.

WARNING
Combustible Liquid
Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or
death.
Do not store fuel, cleaners, oil, etc., near the generator set.

WARNING
High Noise Level
Generator sets in operation emit noise, which can cause hearing damage.
Wear appropriate ear protection at all times.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns.
The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear
appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING
Electrical Generating Equipment
Incorrect operation and maintenance can result in severe personal injury or death.
Make sure that only suitably trained and experienced service personnel perform electrical
and/or mechanical service.

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10-2023 1. IMPORTANT SAFETY INSTRUCTIONS

WARNING
Toxic Hazard
Ethylene glycol, used as an engine coolant, is toxic to humans and animals.
Wear appropriate PPE. Clean up coolant spills and dispose of used coolant in accordance
with local environmental regulations.

WARNING
Combustible Liquid
Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or
death.
Do not use combustible liquids like ether.

WARNING
Automated Machinery
Accidental or remote starting of the generator set can cause severe personal injury or death.
Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery
cables (negative [–] first).

WARNING
Fire Hazard
Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death.
Make sure the generator set is mounted in a manner to prevent combustible materials from
accumulating under the unit.

WARNING
Fire Hazard
Accumulated grease and oil are a fire hazard. Fire can cause severe burns or death.
Keep the generator set and the surrounding area clean and free from obstructions. Repair oil
leaks promptly.

WARNING
Fall Hazard
Falls can result in severe personal injury or death.
Make sure that suitable equipment for performing tasks at height are used in accordance with
local guidelines and legislation.

WARNING
Fire Hazard
Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death.
Keep the generator set and the surrounding area clean and free from obstructions.

WARNING
Pressurized System
Pressurized systems can rupture/leak which can result in severe personal injury or death.
Use appropriate lock out/tag out safety procedures to isolate from all energy sources before
performing any service tasks. Use PPE.

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1. IMPORTANT SAFETY INSTRUCTIONS 10-2023

WARNING
Confined Areas
Confined spaces or areas with restricted access or potential to entrap can cause severe
personal injury or death.
Use appropriate lock out/tag out safety procedures to isolate from all energy sources. Use
PPE. Follow site specific lone worker protocols/permits to work.

CAUTION
Manual Handling Heavy Objects
Handling heavy objects can cause severe personal injury.
Use appropriate lifting equipment and perform tasks with two people where doing so would
make completion of the task safe.

CAUTION
Power Tools and Hand Tools
Tools can cause cuts, abrasions, bruising, puncture injuries.
Only trained and experienced personnel should use power tools and hand tools. Use PPE.

CAUTION
Sharp Edges and Sharp Points
Projecting corners/parts may cause cuts, abrasions and other personal injury.
Use PPE. Be aware of sharp edges and corners/sharp points. Cover/protect them.

NOTICE
Keep multi-type ABC fire extinguishers close by. 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. (Refer to NFPA No. 10
in the applicable region.)

NOTICE
Before performing maintenance and service procedures on enclosed generator sets, make
sure the service access doors are secured open.

NOTICE
Stepping on the generator set can cause parts to bend or break, leading to electrical shorts,
or to fuel leaks, coolant leaks, or exhaust leaks. Do not step on the generator set when
entering or leaving the generator set room.

1.3 Generator Set Safety Code

Before operating the generator set, read the manuals and become familiar with them 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.

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10-2023 1. IMPORTANT SAFETY INSTRUCTIONS

WARNING
Electrical Generating Equipment
Incorrect operation and maintenance can result in severe personal injury or death.
Read and follow all Safety Precautions, Warnings, and Cautions throughout this manual and
the documentation supplied with the generator set.

1.3.1 Generator Set Operating Areas

WARNING
Ejected Debris
Debris ejected during destructive failure can cause serious injury or death by impact,
severing or stabbing.
Do not to stand alongside the engine or alternator while the generator set is running.

• Operators must not stand alongside the engine or alternator while the generator set is running,
unless the risks of doing so have been assessed and adequate mitigation steps have been
taken.
• If there are operation/maintenance procedures that require spending time alongside the
generator set when it is running, take every precaution to perform these tasks safely. Keep time
spent performing these tasks to a minimum.
• Be aware of the product environment. Other equipment may be in operation or energized in the
surrounding area.

1.3.2 Moving Parts Can Cause Severe Personal Injury or

Death
• Keep hands, clothing, and jewelry away from moving parts. 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.
• Before starting work on the generator set, disconnect the battery charger from its AC source,
then disconnect the starting batteries using an insulated wrench, 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.
• If any adjustments must be made while the unit is running, use extreme caution around hot
manifolds, moving parts, etc.

1.3.3 Positioning of Generator Set - Open Sets

The area for positioning the set should be adequate and level, and the area immediately around the
set must be free of any flammable material.

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1. IMPORTANT SAFETY INSTRUCTIONS 10-2023

1.4 Electrical Shocks and Arc Flashes Can Cause

Severe Personal Injury or Death
WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or
death.
Contact with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC or
higher can cause electrical shock and electrical arc flash. Refer to standard NFPA 70E or
equivalent safety standards in corresponding regions for details of the dangers involved and
for the safety requirements.

Guidelines to follow when working on de-energized electrical systems:

• Use proper PPE. Do not wear jewelry and make sure that any conductive items are removed
from pockets as these items can fall into equipment and the resulting short circuit can cause
shock or burning. Refer to standard NFPA 70E for PPE standards.
• De-energize and lockout/tagout electrical systems prior to working on them. Lockout/Tagout is
intended to prevent injury due to unexpected start-up of equipment or the release of stored
energy. Please refer to Locking the Generator Set Out of Service section for more information.
• De-energize and lockout/tagout all circuits and devices before removing any protective shields or
making any measurements on electrical equipment.
• Follow all applicable regional electrical and safety codes.
Guidelines to follow when working on energized electrical systems:

NOTICE
It is the policy of Cummins Inc. to perform all electrical work in a de-energized state.
However, employees or suppliers may be permitted to occasionally perform work on
energized electrical equipment only when qualified and authorized to do so and when
troubleshooting, or if de-energizing the equipment would create a greater risk or make the
task impossible and all other alternatives have been exhausted.

NOTICE
Exposed energized electrical work is only allowed as per the relevant procedures and must
be undertaken by a Cummins authorized person with any appropriate energized work permit
for the work to be performed while using proper PPE, tools and equipment.

In summary:
• Do not tamper with or bypass interlocks unless you are authorized to do so.
• Understand and assess the risks - use proper PPE. Do not wear jewelry and make sure that any
conductive items are removed from pockets as these items can fall into equipment and the
resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE
standards.
• Make sure that an accompanying person who can undertake a rescue is nearby.

1.4.1 Locking the Generator Set Out of Service

Before any work is carried out for maintenance, etc., the generator set must be immobilized. Even if
the generator set is put out of service by pressing the Off switch on the operator panel, the generator
set cannot be considered safe to work on until the engine is properly immobilized, as detailed in the
following procedures.

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10-2023 1. IMPORTANT SAFETY INSTRUCTIONS

NOTICE
Refer also to the engine specific Operator Manual. This manual contains specific equipment
instructions that may differ from the standard generator set.

1.4.1.1 Immobilizing for Safe Working

To immobilize the generator set:
1. Press the Off mode switch on the operator panel to shut down the generator set.
2. Press the Emergency Stop button. This prevents the generator set starting, regardless of the
Start signal source and provides an additional safety step for immobilizing the generator set.

NOTICE
When the Emergency Stop button is pressed, the operator panel indicates a Shutdown

condition. The red Shutdown status LED illuminates and a message is displayed.

NOTICE
Do not cover Emergency stop button in any situation for easy accessibility

NOTICE
This condition is stored in the Fault History.

3. Isolate and lock off the starting battery/batteries.

4. As an additional precaution, thoroughly ventilate the plant room before disconnecting any leads.
5. Isolate and lock off the supply to the heater, where fitted.
6. Isolate and lock off the supply to the battery charger, where fitted.
7. Isolate the fuel supply to the engine.
8. Using an insulated wrench, disconnect the negative (–) cable first on the starting batteries and
control system batteries (if separate).
9. Fit warning notices at each of the above points to indicate Maintenance in Progress — Plant
Immobilized for Safe Working.

1.4.2 AC Supply and Isolation

NOTICE
Local electrical codes and regulations (for example, BS EN 12601:2010 Reciprocating internal
combustion engine driven generating sets) may require the installation of a disconnect
means for the generator set, either on the generator set or where the generator set
conductors enter a facility.

NOTICE
The AC supply must have the correct over current and earth fault protection according to
local electrical codes and regulations. This equipment must be earthed (grounded).

It is the sole responsibility of the customer to provide AC power conductors for connection to load
devices and the means to isolate the AC input to the terminal box; these must comply with local
electrical codes and regulations. Refer to the wiring diagram supplied with the generator set.

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1. IMPORTANT SAFETY INSTRUCTIONS 10-2023

The disconnecting device is not provided as part of the generator set, and Cummins accepts no
responsibility for providing the means of isolation.

1.4.2.1 AmpSentry
Generator sets with PC 3.3 control utilize AmpSentry™ protective relay which includes integral AC
protective functions for the alternator and conductors, if conductors are rated for operation at a
minimum of 100% of the generator nameplate rating.

1.4.3 AC Disconnect Sources

WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or death.
The equipment may have more than one source of electrical energy. Disconnecting one
source without disconnecting the others presents a shock hazard. Before starting work,
disconnect the equipment, and verify that all sources of electrical energy have been removed.

1.5 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 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 copper piping on flexible lines as copper will
become brittle if continuously vibrated or repeatedly bent.
• Make sure all fuel supplies have a positive (+) shutoff valve.
• Make 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.

1.5.1 Spillage
Any spillage that occurs during fueling, oil top-off, or oil change must be cleaned up before starting the
generator set.

1.5.2 Fluid Containment

NOTICE
Where spillage containment is not part of a Cummins supply, it is the responsibility of the
installer to provide the necessary containment to prevent contamination of the environment,
especially water courses and sources.

Fluid containment is incorporated into the base of the generator set, it must be inspected at regular
intervals. Any liquid present should be drained out and disposed of in accordance with local health
and safety regulations. Failure to perform this action may result in spillage of liquids which could
contaminate the surrounding area.
Any other fluid containment area must also be checked and emptied, as described above.

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1.5.3 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 generator set where a flammable
vapor environment can be created, unless the generator set is equipped with an automatic safety
device to block the air intake and stop the engine. The owners and operators of the generator set are
solely responsible for operating the generator set safely. Contact your authorized Cummins distributor
for more information.

1.6 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 system 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.
• Make sure the unit is well ventilated.

1.6.1 Exhaust Precautions

WARNING
Hot Exhaust Gases
Contact with hot exhaust gases can cause severe burns.
Wear personal protective equipment when working on equipment.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns.
The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear
appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING
Toxic Gases
Inhalation of exhaust gases can cause asphyxiation and death.
Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings. Do not
allow exhaust gas to accumulate in habitable areas.

WARNING
Fire Hazard
Contaminated insulation is a fire hazard. Fire can cause severe burns or death.
Remove any contaminated insulation and dispose of it in accordance with local regulations.

The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust
outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position.
Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom,
make sure that vegetation is removed from the vicinity of the exhaust.
The exhaust pipes may have some insulating covers fitted. If these covers become contaminated they
must be replaced before the generator set is run.

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To minimize the risk of fire, make sure the following steps are observed:
• Make sure that the engine is allowed to cool thoroughly before performing maintenance or
operation tasks.
• Clean the exhaust pipe thoroughly.

1.7 Earth Ground Connection

The neutral of the generator set may be required to be bonded to earth ground at the generator set
location, or at a remote location, depending on system design requirements. Consult the engineering
drawings for the facility or a qualified electrical design engineer for proper installation.

NOTICE
The end user is responsible to make sure that the ground connection point surface area is
clean and free of rust before making a connection.

NOTICE
The end user is responsible for making sure that an earthing arrangement that is compliant
with local conditions is established and tested before the equipment is used.

1.8 Decommissioning and Disassembly

NOTICE
Decommissioning and disassembly of the generator set at the end of its working life must
comply with local guidelines and legislation for disposal/recycling of components and
contaminated fluids. This procedure must only be carried out by suitably trained and
experienced service personnel. For more information contact your authorized distributor.

Copyright © 2023 Cummins Inc. 10 A045E599 (Issue 5)

2 Introduction
WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or death.
Make sure that only a trained and experienced electrician makes generator set electrical
output connections, in accordance with the installation instructions and all applicable codes.

WARNING
Electrical Generating Equipment
Faulty electrical generating equipment can cause severe personal injury or death.
Generator sets must be installed, certified, and operated by trained and experienced persons
in accordance with the installation instructions and all applicable codes.

2.1 About This Manual

The purpose of this manual is to provide the users with sound, general information. It is for guidance
and assistance with recommendations for correct and safe procedures, which may from time to time
be updated. It is the user's responsibility to ensure they are aware of any updates to this guidance
before commencing operational activities. Cummins shall not be liable for any operational
consequences arising as a result of not following the guidance outlined in this manual, nor for any
discretionary actions taken by the user in response to recommendations outlined in this manual.
The information contained within the manual is based on information available at the time of going to
print. In line with Cummins policy of continuous development and improvement, information may
change at any time without notice. The users should therefore make sure that before commencing any
work, they have the latest information available. The latest version of this manual is available on
QuickServe Online (https://quickserve.cummins.com).
Users are respectfully advised that, in the interests of good practice and safety, it is their responsibility
to employ competent persons to carry out any installation work. Consult your authorized distributor for
further installation information. It is essential that the utmost care is taken with the application,
installation, and operation of any engine due to their potentially hazardous nature. Careful reference
should also be made to other Cummins literature. A generator set must be operated and maintained
properly for safe and reliable operation.
For further assistance, contact your authorized distributor.

2.1.1 Additional Installation Manual Information

The purpose of this manual is to provide the Installation Engineer with sound, general information for
the installation of the generator set. Refer to the Generator Set Operator Manual for additional
information which must also be read before operating the set.
This manual provides installation instructions for the generator set models listed on the front cover.
This includes the following information:
• Mounting Recommendations - for fastening the generator set to a base and space requirements
for normal operation and service.
• Mechanical and Electrical Connections - covers most aspects of the generator set installation.
• Prestart - checklist of items or procedures needed to prepare the generator set for operation.
• Installation Checklist - reference checks upon completion of the installation.

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2. Introduction 10-2023

This manual does not provide application information for selecting a generator set or designing the
complete installation. If it is necessary to design the various integrated systems (fuel, exhaust, cooling,
etc.), additional information is required. Review standard installation practices. For engineering data
specific to the generator set, refer to the Specification and Data Sheets. For application information,
refer to Application Manual T-030, "Liquid Cooled Generator Sets." To find this manual online:
1. Go to powersuite.cummins.com
2. Click on "Login" on the Home page.
3. Click on "Library".
4. Click on "Technical Documents".
5. Click on "Technical information".
6. Click on "Liquid Cooled Genset Application Manual".

2.2 Schedule of Abbreviations

This list is not exhaustive. For example, it does not identify units of measure or acronyms that appear
only in parameters, event/fault names, or part/accessory names.

ABBR. DESCRIPTION ABBR. DESCRIPTION

AC Alternating Current HMI Human-Machine Interface
ADCS Advanced Digital Control LCD Liquid Crystal Display
System
ASTM American Society for Testing LED Light-Emitting Diode
and Materials (ASTM
International)
AVR Automatic Voltage Regulator MIL STD Military Standard
CB Circuit Breaker NATO North Atlantic Treaty
Organization
CT Current Transformer NFPA National Fire Protection Agency
DC Direct Current NO Normally Open
DCS Digital Control System PT Potential Transformer
ECM Engine Control Module OOR Out of Range
EMI Electromagnetic interference PCC PowerCommand™ Control
EN European Standard PPE Personal Protective Equipment
ESD Electro Static Discharge PWM Pulse-Width Modulation
E-Stop Emergency Stop RMS Root Mean Square
Genset Generator Set SAE Society of Automotive Engineers
GFCI Ground Fault Circuit Interrupter SW_B+ Switched B+
GFI Ground Fault Interrupter USB Universal Serial Bus
GND Ground

2.3 Related Literature

Before any attempt is made to operate the generator set, the operator should take time to read all of
the manuals supplied with the generator set, and to familiarize themselves with the warnings and
operating procedures.

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10-2023 2. Introduction

NOTICE
A generator set must be operated and maintained properly if you are to expect safe and
reliable operation. The Operator manual includes a maintenance schedule and a
troubleshooting guide.
The Health and Safety manual must be read in conjunction with this manual for the safe
operation of the generator set:

• Health and Safety Manual (0908-0110)

The relevant manuals appropriate to your generator set are also available, the documents below are in
English:
• Operator Manual for QSK23-G3 with PowerCommand 3.3 (A045E611)
• Operator Manual for QSK23-G3 with PowerCommand 3.3 MLD (A045E652)
• Installation Manual for QSK23-G3 with PowerCommand 3.3 or 3.3 MLD (A045E599)
• Generator Set Service Manual for QSK23-G3 with PowerCommand 3.3 or 3.3 MLD (A045L346)
• Recommended Spares List (RSL) for C750 D6 and C750 D6 (SPEC J-K) is (A050F729)
• Recommended Spares List (RSL) for C825 D5 and C825 D5 (SPEC J-K) is (A050F730)
• Recommended Spares List (RSL) for C800 D6 and C800 D6 (SPEC J-K) (A050F731)
• Recommended Spares List (RSL) for C900 D5 and C900 D5 (SPEC J-K) (A050F732)
• Parts Manual for QSK23-G3 with PowerCommand 3.3 or 3.3 MLD (A050F726 )
• Standard Repair Times - ET Family (A030M221)
• Service Tool Manual (A043D529)
• Failure Code Manual (F1115C)
• Application Manual T-030, Liquid Cooled Generator Sets - for application information
(A040S369)
• Engine Operation & Maintenance Manual for QSK23 (4021374)
• Warranty Manual (A040W374)
• Global Commercial Warranty Statement (A028U870)

2.3.1 Further Information - Literature

Contact your authorized distributor for more information regarding related literature for this product.

2.4 After Sales Services

Cummins offers a full range of maintenance and warranty services.

2.4.1 Maintenance
WARNING
Electrical Generating Equipment
Incorrect operation and maintenance can result in severe personal injury or death.
Make sure that only suitably trained and experienced service personnel perform electrical
and/or mechanical service.

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2. Introduction 10-2023

For expert generator set service at regular intervals, contact your local distributor. Each local
distributor offers a complete maintenance contract package covering all items subject to routine
maintenance, including a detailed report on the condition of the generator set. In addition, this can be
linked to a 24-hour call-out arrangement, providing year-round assistance if necessary. Specialist
engineers are available to maintain optimum performance levels from generator sets. Maintenance
tasks should only be undertaken by trained and experienced technicians provided by your authorized
distributor.

2.4.2 Warranty
For details of the warranty coverage for your generator set, refer to the Global Commercial Warranty
Statement listed in the Related Literature section.
In the event of a breakdown, prompt assistance can normally be given by factory trained service
technicians with resources to undertake all minor and many major repairs to equipment on site.
Extended warranty coverage is also available.
For further warranty details, contact your authorized service provider.

NOTICE
Damage caused by failure to follow the manufacturer's recommendations will not be covered
by warranty. Contact your authorized service provider.

2.4.2.1 Warranty Limitations

For details of the warranty limitations for your generator set, refer to the warranty statement applicable
to the generator set.

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3 System Overview
This section provides an overview of the generator set.

3.1 Generator Set Identification

Each generator set is provided with a nameplate similar to that shown below. The nameplate provides
information unique to the generator set.

3.1.1 Nameplate - Open Generator Set

FIGURE 1. TYPICAL OPEN GENERATOR SET NAMEPLATE

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3. System Overview 10-2023

3.1.2 Nameplate

FIGURE 2. TYPICAL GENERATOR SET NAMEPLATE

NOTICE
For higher temperature or altitude, please contact factory for available outputs.

3.2 Generator Set Components

The main components of a typical QSK23-G3/G9 engine generator set are shown below, and referred
to within this section.
There are various options listed although they may not be available for all models.

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10-2023 3. System Overview

No Description No Description
1 Engine - QSK23 G3/G9 6 Skid
2 Alternator 7 Radiator
3 Controller PC3300 (Rear Side Mounted) 8 Battery Tray Installation
4 Controller PC3300 (Left Side Mounted 9 Circuit Breaker Box
5 Normal Duty Air Cleaner 10 Sump Drain Pump

FIGURE 3. TYPICAL QSK23-G3/G9 ENGINE GENERATOR SET

3.3 Generator Set Rating

For details of the generator set rating, refer to the generator set nameplate. For operation at
temperatures or altitudes above those stated on the nameplate, a derate may be necessary.

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3. System Overview 10-2023

3.4 Engine

Item Description Item Description

1 Coolant Filter 6 Oil Filler Cap
2 Crankcase Breather 7 Dip Stick
3 Oil Filters 8 Crankcase Breather Drain Cup
4 Crankcase Breather Drain Cup 9 Crankcase Breather
5 Engine Oil Drain Plug 10 Fuel Filters

FIGURE 4. TYPICAL ENGINE COMPONENTS (QSK23-G3)

3.5 Sensors
Various generator set parameters are measured by sensors, and the resulting signals are processed
by the control board.
Engine-mounted sensors monitor a number of different systems, such as:
• Lube Oil Pressure
• Cooling System Temperature

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10-2023 3. System Overview

3.6 Pyrometers - Engine Exhaust

A pyrometer measures engine exhaust gas temperature. A separate temperature meter is used to
monitor each exhaust outlet elbow.

3.6.1 Pyrometer Position

FIGURE 5. PYROMETER POSITION

3.7 System Options

3.7.1 Introduction
This section provides information for system options that require installation or customer connections
before commissioning the generator set. For more information regarding system options, refer to the
operator and service manual.

3.7.2 Battery Charger

Battery chargers can be wall, bench, or skid mounted. For more information, see Section 9.11 on
page 67.

3.7.3 Fuel Tank

A fuel tank may supplied with the set to provide fuel for daily generator set operation. Integrated fuel
tank is included in the QSK23.
Open generator set- 1250 intergrated tank option
Enclosed generator set- 1000 intergrated tank option

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3. System Overview 10-2023

Item Description Item Description

1 Filler cap 5 Valve
2 Tank (capacity 450-1350 litres (118- US Gals) 6 Fuel level gauge
3 Fuel return (from engine) 7 Fuel level switch
4 Hand pump

FIGURE 6. STANDALONE FUEL TANK

3.7.4 Heaters
3.7.4.1 Heater Supply and Isolation
An external power supply is required for the operation of the generator set heaters.

NOTICE
If not already provided, it is the sole responsibility of the customer to provide the power
supply and the means to isolate the AC input to the terminal box. Cummins accepts no
responsibility for providing the means of isolation.

3.7.4.2 Alternator Heaters

Alternator heaters are used to help keep the alternator free of condensation when the generator set is
not running. For more information on alternator heater components and specifications, refer to
Section 9.8 on page 65.

3.7.4.3 Coolant Heater

Coolant heaters heat the coolant to maintain a minimum engine temperature when the generator set is
not running. For more information on coolant heater components and specifications, see Section 9.7
on page 65.

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10-2023 3. System Overview

3.7.4.4 Control Box Heater

A control box heater provides a means of humidity and temperature control of the control box interior.
It protects the components when the generator set is subjected to varying ambient air conditions
during extended periods of non-use. For more information on heater components and wiring, see
Section 9.9 on page 66.

3.7.5 Relays
3.7.5.1 Ground Fault Relays
Ground fault relays can be used in the following applications:
• Local CT for 4-pole transfer switch
• Remote CT for 3-pole transfer switch
For more information on ground fault relay components and wiring, see Section 8.4.

3.7.6 Motorized Circuit Breaker

NOTICE
The circuit breaker does not close if the run/idle switch is in the idle position.

Circuit Breakers are designed to protect electrical systems from damage caused by overloads, short
circuits and equipment ground faults. Motorized circuit breakers are usually electrically charged via a
charging motor and are closed and tripped via coils that are remotely controlled at a predetermined
overcurrent setting.

Circuit breakers are equipped with a trip system to protect power circuits and loads. Trip systems use
a set of current transformers (called CTs or sensors) to sense current, a trip unit to evaluate the
current, and a tripping solenoid to trip the circuit breaker. Adjustable rotary switches on the trip unit
allow the user to set the proper overcurrent or equipment ground-fault current protection required in
the electrical system. If current exceeds a set value for longer than its set time delay, the trip system
opens the circuit breaker. Alarms may be programmed for remote indications. Measurements of
current, voltage, frequency, power, and power quality optimize continuity of service and energy
management. The trip units can be changed on-site.

When operating the generator set in auto mode, the circuit breaker is only operated automatically, as
the controller takes charge of opening and closing the circuit breaker. If fault conditions appear
(overload or short circuit), the circuit breaker opens automatically.

If the circuit breaker trips, locate the source of the overload and correct as necessary. Manually reset
the breaker to reconnect the load to the generator.

For additional information refer to the manufacturer's literature.

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3. System Overview 10-2023

3.7.6.1 External Busbar Connection Procedure

WARNING
Electric Shock
Overloading the socket may result in personal injury due to electrical shock or serious
damage to the equipment.
Do not overload the external electrical sockets above the specified rating.

NOTICE
When making bus bar connections make sure fasteners are tight. When using Cam-Lok
connections make sure connectors are fully locked. Procedures are for either type of
connections.

1. Make sure the generator set is not running.

2. Make sure the generator set is isolated and in a safe condition before connecting to the bus bar.
3. Use an approved cable and fixings to connect the load to the bus bar.
4. Make sure that the load is not more than the load rating for the connection and the cable.

Copyright © 2023 Cummins Inc. 22 A045E599 (Issue 5)

4 Installation Overview
These installation recommendations apply to typical installations with standard model generator sets.
Whenever possible, these recommendations also cover factory designed options or modifications.
However, because of the many variables in any installation, it is not possible to provide specific
recommendations for every situation. If there are any questions not answered by this manual, contact
your nearest authorized distributor for assistance.

4.1 Application and Installation

A power system must be carefully planned and correctly installed for proper operation. This involves
two essential elements.
• Application (as it applies to generator set installations) refers to the design of the complete
power system that usually includes power distribution equipment, transfer switches, ventilation
equipment, mounting pads, cooling, exhaust, and fuel systems. Each component must be
correctly designed so the complete system will function as intended. Application and design is
an engineering function generally done by specifying engineers or other trained specialists.
Specifying engineers or other trained specialists are responsible for the design of the complete
power system and for selecting the materials and products required.
◦ Generator sets are designed and manufactured for specific environments.
▪ Open generator sets are designed for use inside a building or plant where they will
not be subjected to extreme environments.
▪ Enclosed generator sets are designed for use outside, with features designed to
enable operation in a wide range of climates.
• Installation refers to the actual set-up and assembly of the power system. The installers set up
and connect the various components of the system as specified in the system design plan. The
complexity of the system normally requires the special skills of qualified electricians, plumbers,
sheet-metal workers, etc. to complete the various segments of the installation. This is necessary
so that all components are assembled using standard methods and practices.

4.2 Safety Considerations

The generator set has been carefully designed to provide safe and efficient service when properly
installed, maintained, and operated. However, the overall safety and reliability of the complete system
is dependent on many factors outside the control of the generator set manufacturer. To avoid possible
safety hazards, make all mechanical and electrical connections to the generator set exactly as
specified in this manual. All systems external to the generator (fuel, exhaust, electrical, etc.) must
comply with all applicable codes. Make certain all required inspections and tests have been completed
and all code requirements have been satisfied before certifying the installation is complete and ready
for service.

WARNING
Fall Hazard
Falls can result in severe personal injury or death.
Make sure that suitable equipment for performing tasks at height are used in accordance with
local guidelines and legislation.

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4. Installation Overview 10-2023

4.3 Standby Heating Devices

Cummins requires installing standby generator sets (life safety systems) with engine jacket water
coolant heaters in order to ensure a 10 second start. Jacket water coolant heaters are also
recommended in prime and continuous applications where time and load acceptance is to be
minimized.
The jacket water coolant heater provided by Cummins rated to provide the above requirements in
ambient temperatures as low as 4 °C (40 °F). Although most Cummins generator sets will start in
temperatures down to –32 °C (–25 °F) when equipped with engine jacket water coolant heaters, it
might take more than 10 seconds to warm the engine before a load can be applied when ambient
temperatures are below 4 °C (40 °F).
On generator sets equipped with a graphic display, the Low Coolant Temperature message, in
conjunction with illumination of the Warning LED, is provided to meet the current requirements. The
engine cold sensing logic initiates a warning when the engine jacket water coolant temperature falls
below 21 °C (70 °F). In applications where the ambient temperature falls below 4 °C (40 °F), or there
exists a high amount of cold airflow, the jacket water coolant heater may not provide the necessary
heating. Under these conditions, although the generator set may start, it may not be able to accept
load within 10 seconds. When this condition occurs, check the coolant heaters for proper operation. If
the coolant heaters are operating properly, other precautions may be necessary to warm the engine
before applying a load.

4.4 Product Modifications

Agency certified products purchased from Cummins 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 and national codes and standards. Product modifications
must be submitted to the local authority having jurisdiction for approval.

4.5 Derating Factors

Engine power and resulting electrical output decrease as ambient temperature or altitude increases.
For derating factors applicable at specific sites, contact your authorized distributor.

Copyright © 2023 Cummins Inc. 24 A045E599 (Issue 5)

5 Specifications
5.1 Generator Set Specifications
TABLE 1. C825 D5, C825D5E, C825 D5e, C900 D5, C900D5E, C900 D5e, C750 D6, C800 D6
SPECIFICATIONS

MODELS C825 D5 & C825 D5 (Spec J-K), C825D5E & C825 D5e (Begin Spec K),
C900 D5 & C900 D5 (Spec J-K), C900D5E & C900 D5e (Begin Spec K),
C750 D6 & C750 D6 (Spec J-K), C800 D6 & C800 D6 (Spec J-K)
Engine
Cummins Diesel Series QSK23-G3/G9
Generator kVA/kW Rating See generator set nameplate for rating information.
Engine Fuel Connection
Inlet/Outlet Thread Size Refer to generator set outline drawing supplied (A066H639)
Maximum Weight Refer to generator set outline drawing supplied (A066H639)
Fuel
Max. Fuel Inlet Restriction 203 mm Hg (8 inHg)
Fuel Pump Flow Rate 685 L/hr (181 US gal/hr)
Exhaust 1500 RPM 1800 RPM
Exhaust gas flow at set rated load 140.1 m3/min 179.1 m3/min
Exhaust gas temperature 550° C 482° C
Maximum exhaust back pressure 10.1 kPa 10.1 kPa
Electrical System
Starting Voltage 24 Volts DC
CCA (minimum) 840A
Cooling System 136.5 L (36 US gal)
Capacity with Standard Radiator 109.5 L (28.9 US gal)
Capacity with optional Radiator
Lubricating System
Oil Capacity with Filters 103 L (27.2 US gal)

5.2 Engine Fuel Consumption

TABLE 2. FUEL CONSUMPTION L/HR (GAL/HR) AT 1500 RPM (50 HZ)

Model C825 D5 & C825 D5 C900 D5 & C900 D5

(Spec J-K) (Spec J-K)
Engine QSK23-G3 QSK23-G3
Engine Performance Data at 50 Hz1 166.2 (36.5) 178 (39.1)
1. Standby/Full Load
Refer to data sheets for other applications. In line with the CPG policy of continuous improvement, these figures
are subject to change.

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5. Specifications 10-2023

TABLE 3. FUEL CONSUMPTION L/HR (GAL/HR) AT 1800 RPM (60 HZ)

Model C750 D6 & C750 D6 C800 D6 & C800 D6

(Spec J-K) (Spec J-K)
Engine QSK23-G3 QSK23-G3
Engine Performance Data at 60 Hz1 196.5 (43.2) 212.4 (46.7)
1. Standby/Full Load
Refer to data sheets for other applications. In line with the CPG policy of continuous improvement, these figures
are subject to change.

TABLE 4. FUEL CONSUMPTION L/HR (GAL/HR) AT 1500 RPM (50 HZ)

Model C825D5E & C825 D5e (Spec K) C900D5E & C900 D5e (Spec K)
Engine QSK23- G9 QSK23-G9
Engine Performance Data at 50 Hz1 166.7 (44) 185.1 (48.8)
1. Standby/Full Load
Refer to data sheets for other applications. In line with the CPG policy of continuous improvement, these figures
are subject to change.

Copyright © 2023 Cummins Inc. 26 A045E599 (Issue 5)

6 Installing the Generator Set
Generator set installations must be engineered so that the generator set will function properly under
the expected load conditions. Use these instructions as a general guide only. Follow the instructions of
the consulting engineer when locating or installing any components. The complete installation must
comply with all local and state building codes, fire regulations, and other applicable regulations.
Requirements to be considered prior to installation are:
• Level mounting surface
• Adequate cooling air
• Adequate fresh induction air
• Discharge of generator set air
• Non-combustible mounting surface
• Discharge of exhaust gases
• Electrical connections
• Accessibility for operation and servicing
• Noise levels
• Vibration isolation
• Environmental conditions:
◦ High and low temperatures, humidity
◦ Rain and snowfall
◦ Flood risk
◦ Period of exposure to detrimental weather conditions
◦ Wind

NOTICE
Depending on the location and intended use, ensure that international, national or local laws
and regulations regarding Air Quality Emissions have been observed and complied with. Be
sure to consult local pollution control or air quality authorities before completing
construction plans.

6.1 Transportation
WARNING
Heavy Load
Incorrect lifting or repositioning can cause severe personal injury or death.
Make sure that only suitably trained and experienced personnel transport and handle
generator sets and associated components.

WARNING
Heavy Load
Incorrect lifting or repositioning can cause severe personal injury or death.
Do not lift the generator set by attaching to the engine or alternator lifting points. Do not
stand under or near the generator set when lifting.

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6. Installing the Generator Set 10-2023

NOTICE
On an enclosed generator set, the canopy doors must be locked before re-positioning and
must remain locked during transportation and siting.

• Ensure the generator set is prepared for transport. If necessary drain fluids and ensure that acid
or fumes do not leak from the battery (where applicable).
• If the generator set is transported over long distances, protect it against environmental
influences by sealing it in a plastic cover or similar.
• Ensure the generator set is secured to the vehicle with suitable securing straps. Wooden chocks
and pallets alongside the securing straps can prevent movement during transportation.
• If required, attached impact indicators to the generator set. Upon delivery, check these impact
indicators and contact the transport company immediately if an impact has been detected.
Impacts can cause serious damage to the generator set and its components.
• Ensure that the generator set cannot turn over during transportation.
• Do not overload the transport vehicle. Under no circumstances should the generator set be
started while inside a truck.
• Lifting eyes, where fitted, are to be checked at regular intervals to ensure they are damage free
and tight.

6.2 Location
WARNING
Electrical Generating Equipment
Incorrect operation and maintenance can result in severe personal injury or death.
Make sure that only suitably trained and experienced service personnel perform electrical
and/or mechanical service.

WARNING
Incorrect installation
Incorrect installation of the generator set, 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 mechanical
component installation.

NOTICE
Depending on your location and intended use, additional laws and regulations may require
for you to obtain an air quality emissions permit before beginning installation of your
generator set. Be sure to consult local pollution control or air quality authorities before
completing your construction plans.

Generator set location is decided mainly by related systems such as ventilation, wiring, fuel, and
exhaust. The set should be located as near as possible to the main power service entrance. Exhaust
gases must not be able to enter or accumulate around inhabited areas.
Provide a location away from extreme ambient temperatures and protect the generator set from
adverse weather conditions.
Use the following information to locate the generator set for optimal operating conditions:
Surface: Concrete or compacted gravel with the generator set resting on solid, poured concrete
blocks, or timber blocks spaced at reasonable intervals around the perimeter of the generator set.
Leveling: Level the generator set from side-to-side within 3.5°, and end-to-end within 2.5°.

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10-2023 6. Installing the Generator Set

Placement:
• Generator sets should be a minimum of 5 m (16.4 ft) apart to allow for adequate access.
• Make sure that the air inlets are not obstructed by surrounding trees, buildings, or other
obstructions.
• Make sure noise distribution (to prevent echoing) is kept to a minimum.
• Consider exhaust for immediate neighbors.
• The prevailing wind direction should be considered so that the engine combustion air inlet is
upwind and the exhaust discharge is downwind.
• The immediate area around the proposed location of the mounting surface should be evaluated
for proper drainage so that moisture run-off is sufficient to prevent ponding around the unit(s).

6.3 Moving the Generator Set

WARNING
Heavy Load
Incorrect lifting or repositioning can cause severe personal injury or death.
Make sure that only suitably trained and experienced personnel transport and handle
generator sets and associated components.

WARNING
Heavy Load
Incorrect lifting or repositioning can cause severe personal injury or death.
Do not lift the generator set by attaching to the engine or alternator lifting points. Do not
stand under or near the generator set when lifting.

WARNING
Mechanical Hazard
Failed components may be ejected or operate incorrectly which can cause severe personal
injury or death.
Do not climb the generator set; this may damage critical parts.

NOTICE
Make sure that any shipping brackets supplied with the generator set are fitted, before
moving the generator set. Failure to install the shipping brackets before moving may result in
damage to the generator set.

NOTICE
Access or service doors must be closed and locked before repositioning, and they must
remain locked during transportation and siting.

It is essential that there are sufficient trained and experienced personnel in attendance to make sure
the lifting and transportation of the generator set is undertaken in a safe and appropriate manner, and
in accordance to local guidelines and legislation.

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6. Installing the Generator Set 10-2023

Before lifting the generator set, lifting points, angle of slings, mass, access to intended site, and the
distance of movement should all be taken into account when organizing a suitable crane/hoist. Consult
the generator set information supplied with the generator set for details of dimensions and mass.
• Make sure the fuel tank is empty.
• Make sure that the crane operating area is able to support the mass of the crane and the
generator set.
• Make sure the equipment used for lifting is adequate to support the weight of the generator set.
• Attach the lifting device to the lifting points only using suitable shackles, chains, and spreader
bars.
• Slowly tighten the slings. Inspect the lifting attachments before commencing a full lift to make
sure they are attached correctly.
• Hoist the generator set slowly using the indicated lifting points only.
• Guide the generator set with ropes at a safe distance to prevent uncontrolled rotation when
positioning the generator set.
• Move the generator set to the desired location and place in position, bringing the set down
slowly.
• Loosen the slings; unhook and remove the shackles.

6.3.1 Rigging Instructions

WARNING
Heavy Load
Incorrect lifting or repositioning can cause severe personal injury or death.
Do not lift the generator set by attaching to the engine or alternator lifting points. Do not
stand under or near the generator set when lifting.

WARNING
Heavy Load
Incorrect lifting or repositioning can cause severe personal injury or death.
Make sure that only suitably trained and experienced personnel transport and handle
generator sets and associated components.

1. Consult the generator set outline drawing for weight and center-of-gravity information. Consult
enclosed generator set outline drawing for lifting instructions.
2. Attach cables from the lifting lugs to a spreader bar. Never make the spreader bar cable
attachment points wider than the attachment points on the skid or the bars. Make sure cables do
not touch any other part of the generator set other than the skid.

NOTICE
Spreader bar cable attach points width "Y" must never be wider than skid cable attach
points "X." Distance "X" is the narrowest width.

NOTICE
Angle B must be slightly greater than angle A. Angle B should be as close to 90 degrees
as possible to provide a stable lift.

3. With pedestal box (not shown), the spreader bars (front and back) should be used to clear the
pedestal box and the attachment cables must be as vertical as possible.

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10-2023 6. Installing the Generator Set

NOTICE
The lifting angle (angle C) must not exceed 20° from vertical.

Item Description No. Description

A Angle A 1 Spreader Bar
B Angle B 2 Lifting Point
C Angle C (20° Maximum) 3 Lifting Cables
X The Narrowest Width (On the Skid) 4 Center of Gravity
Y This Distance Must be Less than Distance "X"

FIGURE 7. RIGGING
Lifting for Enclosed Generator Set:
1. Attach the lifting device to the lifting points on the skid, using suitable cables, chains and
spreader bar.
2. Tighten the cables and ensure that they are attaced correctly.
3. Hoist the generator set and move it carefully to the desired location. Guide the generator set with
ropes from a safe distance to prevent uncontrolled rotation when positioning the generator set.
Bring the set down slowly.
4. Loosen the slings and remove the lifitng cables attached to the generator set.

WARNING
Do not lift the enclosed generator set from the lifting points of enclosure. Only Enclosure
should be lifted from the lifting points on the enclosure.

NOTICE
Lifitng lugs for enclosed generator set would be provided in a kit, along with the generator
set.

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6. Installing the Generator Set 10-2023

6.4 Mounting
Generator sets are mounted on a steel skid that provides proper support. The engine-generator
assembly is isolated from the skid frame by rubber mounts that provide adequate vibration isolation for
normal installations. Where required by building codes or special isolation needs, generator sets may
be mounted on rubber pads or mechanical spring isolators.

NOTICE
The use of unapproved isolators may result in harmful resonances and may void the
generator set warranty.

Mount the generator set on a substantial and level base such as a concrete pad. A non-combustible
material must be used for the pad.
Use 16 mm (5/8 in) or anchored mounting bolts to secure the generator set bedframe to the base. Use
a flat washer and hexagonal nut for each bolt (see Figure 8). The 38 x 152 mm (1½ x 6 in) pipe
inserted over the mounting bolts allows minor adjustment of the bolts to align them to the holes in the
bedframe.
The fixing centers for the mounting bolts can be found on the generator set Outline Drawing.

No. Description No. Description

1 Generator Bedframe Flange 5 38 mm x 152 mm Pipe (1½ inch x 6 inch)
2 Hexagonal Nut 6 Mounting Bolt Set in Concrete
3 Flat or Bevel Washer 7 305 mm (12 inch)
4 Mounting Base on Concrete

FIGURE 8. BOLT DIAGRAM

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10-2023 6. Installing the Generator Set

6.5 Vibration Isolator Installation and Adjustment

Procedure (For IGB)
This procedure covers the procedure to install vibration isolators (Part Number - A008F116 and
A008F117).
1.Install the vibration isolators on the generator set support structure using the positions indicated on
the drawings supplied see Section B.1 on page 87. The isolators should be shimmed or grouted to
make sure that all of the isolator bases are within 0.25 inch (6 mm) elevation of each other. The
surface that the isolator bases rest on must also be flat and level. Lock the isolators in place with
ground fixings. For additional information refer to the Application Manual T-030, Liquid Cooled
Generator Sets.
Go to www.powersuite.cummins.com
Click on "Application & Technical Manuals" on the Home page.
Click on "Liquid Cooled Genset Application Manual"

FIGURE 9. ISOLATOR
2. Place the generator set onto the isolators while aligning the skid's mounting with the threaded
isolator hole.

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Part Number Dim A Part Number Dim A

*
0232-3710-01 0.9 mm 0232-3710-05 1.9 mm
0232-3710-02 1.9 mm 0232-3710-06* 3.4 mm
0232-3710-03 3.4 mm 0232-3710-07 0.38 mm
* *
0232-3710-04 0.9 mm 0232-3710-08 0.38 mm
*
No finish

FIGURE 10. SHIM

3. Once the generator set is in position, the set may require adjusting so that the set is level.
4. If the generator set is not yet level, adjust the level using shims between the isolator and skid until
the set is level.
5. Once all isolators have been set, tighten the isolator mounting bolts (1) to 170 Nm +/- 17 Nm.

6.6 Access to Generator Set

Generally, at least 1 meter (3.3 ft) of clearance should be provided on all sides of the generator set for
maintenance and service access. (Increase clearance by width of door if optional housing is used.) A
raised foundation or slab of 152 mm (6 inches) or more above floor level will make servicing easier.
Lighting should be adequate for operation, maintenance and service operations and should be
connected on the load side of the transfer switch so that it is available at all times.

6.7 Generator Set Long Term Storage

If long term storage of the generator set is required refer to the Long Term Storage section in the
generator set service manual.
Fan belt drive shelf life is 5 Years.

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7 Mechanical Connections
The generator set mechanical system installation includes connecting the fuel, exhaust, ventilation,
and cooling systems. Before starting any type of fuel installation, all pertinent state and local codes
must be complied with and the installation must be inspected before the unit is put in service.

7.1 Fuel System

Cummins engines normally use a diesel fuel specified to ASTM D975 grade 2 or BS EN 590:2000 is
for automotive diesel, BS 2869:2010+A1:2011 Fuel oils for agricultural, domestic and industrial
engines and boilers.
In all fuel system installations, cleanliness is of the utmost importance. Make every effort to prevent
entrance of moisture, dirt, or contaminants of any kind into the fuel system. Clean all fuel system
components before installing.

NOTICE
A fuel filter/strainer/water separator of 100-120 mesh or equivalent (approximately 150
microns nominal) must be fitted between either the main tank and day tank, or between the
main tank and the engine.

Use only compatible metal fuel lines to avoid electrolysis when fuel lines must be buried. Buried fuel
lines must be protected from corrosion.

NOTICE
Never use galvanized or copper fuel lines, fittings, or fuel tanks. Condensation in the tank
and lines combines with the sulfur in diesel fuel to produce sulfuric acid. The molecular
structure of the copper or galvanized lines or tanks reacts with the acid and contaminates the
fuel.

An electric solenoid valve in the supply line is recommended for all installations and required for
indoor automatic or remote starting installations. Connect the solenoid wires to the generator set
“Switched B+” circuit to open the valve during generator set operation.
Separate fuel return lines to the day tank or supply tank must be provided for each generator set in a
multiple-set installation to prevent the return lines of idle sets from being pressurized. Fuel return lines
must not contain a shutoff device. Engine damage will occur if the engine is run with the return fuel
lines blocked or restricted.

NOTICE
Never install a shutoff device in fuel return line(s). If fuel return line(s) is blocked or exceeds
fuel restriction limit, engine damage will occur.

NOTICE
A base mounted fuel tank may be part of the generator set build. An additional external fuel
system may be required if the on board fuel capacity is not sufficient for the application.

7.1.1 Fuel Return Restrictions (or Pressure) Limit

Fuel return drain restriction (consisting of friction head and static head) between the engine injector
return line connection and the fuel tank must not exceed the limit stated in the model-specific
generator set Specification Sheet.

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7.1.2 Fuel Line Connections

WARNING
Combustible Liquid
Fuel leaks are a fire and explosion hazard which can cause severe personal injury or death.
Always use flexible tubing between the engine and fuel supply to avoid line failure and leaks
due to vibration. The fuel system must meet all application codes.

WARNING
Combustible Liquid
Ignition of fuel is a fire and explosion hazard which can cause severe personal injury or
death.
Do not route fuel lines near electrical wiring.

WARNING
Hot Surface
Hot surfaces can ignite fuel. Ignited fuel is a fire and explosion hazard which can cause
severe burns or death.
Do not route fuel lines near hot exhaust parts.

NOTICE
Fuel lines must be routed and secured to maintain a 12.7 mm (½ inch) minimum clearance
from electrical wiring and a 51 mm (2 inches) minimum clearance from hot exhaust parts.

Flexible lines for connecting between the engine and the skid mounted fuel tank (if fitted) are supplied
as standard equipment.
Flexible lines for connecting between the engine and an external fuel supply must be used between
the engine fuel system, and the fuel supply and return lines to protect the fuel system from damage
caused by vibration, expansion, and contraction.
For additional information refer to T-030 Application Manual.

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No. Description No. Description

1 Valve, Check 3 Hose, Fuel
2 Adapter, Fuel Line 4 Hose, Fuel

FIGURE 11. FUEL SYSTEM WITH FUEL TANK (ENCLOSED SET)

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No. Description No. Description

1 Valve, Check 4 Hose, Fuel
2 Hose, Fuel 5 Adapter, Fuel Line
3 Kit, Hose 7 Adapter, Fuel Line

FIGURE 12. FUEL SYSTEM WITH FUEL TANK

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No. Description No. Description

1 Day Tank/Skid Mounted Fuel Tank 9 Fill Pipe
2 Engine Fuel Pump 10 Main Fuel Tank
3 Shut Off Valve 11 Supply Line
4 Float Switch 12 Larger Overflow Line 120 Mesh Fuel Strainer
5 Vented Fill Cap 13 120 Mesh Fuel Strainer
6 Injector Fuel Return Line 14 Fuel Transfer Pump Electric Motor Driven
7 Connect to AC Output 15 Baffle
8 Vent Pipe 16 25.4 mm (1 inch) Clearance

FIGURE 13. TYPICAL EXTERNAL FUEL SUPPLY INSTALLATION

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7.1.2.1 External Fuel Line Connections

No Description No Description
1 Fuel Filler Neck 3 Hose, Fuel
2 Adapter, Fuel Line 4 Hose, Fuel

FIGURE 14.

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External Fuel Lines Connection for Fuel Filling:

1. Unfasten the External Fuel hose connection opening on the enclosure.
2. Insert the external fuel hose through the opening.
3. Attach the fuel hose to the Fuel filler neck on the skid.

7.1.3 Engine Fuel Connections

Identification tags are attached to the fuel supply line and fuel return line connections. All models
require a fuel return line from the injectors to the tank.

7.1.4 Supply Tank

The fuel supply tank, day tank, or other reservoir must be arranged so that the highest fuel level does
not exceed the maximum height above the fuel injectors specified for the engine. The lowest level
must not fall below the specified lift height of the engine fuel lift pump. In critical start applications, the
lowest level should not be less than 150 mm (6 inches) above the engine fuel pump inlet to make sure
there is no air in the fuel line during startup. Provisions must be made for draining or pumping out
water.
For critical start applications, where generator sets are paralleled or must satisfy emergency start-time
requirements, it is recommended that a fuel tank or reservoir be located such that the lowest possible
fuel level is not less than 150 mm (6 in) above the fuel pump inlet. This will prevent air from
accumulating in the fuel line while the generator set is in standby, eliminating the period during startup
when it has to be purged.
Locate the fuel tank as close as possible to the generator set and within the restriction limitations of
the fuel pump.
Install a fuel tank that has sufficient capacity to supply the generator set depending on its application:
• Continuous power
• Prime power
• Standby power
Refer to the Engine Fuel Consumption section for fuel consumption data.
If the fuel inlet restriction exceeds the defined limit due to the distance/customer-supplied plumbing
between the generator set and the main fuel tank, a transfer tank (sometimes referred to as a day
tank) and auxiliary pump will also be required. If an overhead main fuel tank is installed, a transfer
tank and float valve will be required to prevent fuel head pressures from being placed on the fuel
system components.
For additional information on the size and installation of a supply tank for the application, consult your
local authorized Cummins distributor or dealer.

7.1.5 Fuel Inlet Pressure/Restriction Limit

Engine performance and fuel system durability is compromised if the fuel inlet pressure or restriction
limits are not adhered to. Fuel inlet pressure or restriction must not exceed the limits stated in the
model-specific generator set Specification Sheet.

7.1.6 Fuel Additives

NOTICE
It is the responsibility of the user to ensure that the correct additives and installation of an
external fuel supply is designed to meet the local climate conditions.

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Cummins engines are designed, developed, rated, and built to operate on commercially available
diesel fuel, therefore, it is not our policy to recommend fuel additives. However in certain situations,
when available fuels are of poor quality or problems exist which are peculiar to certain operations or
climate conditions, additives can be used. Consult with the fuel supplier and your local distributor prior
to the use of fuel additives.

7.2 Exhaust System

WARNING
Toxic Gases
Inhalation of exhaust gases can cause asphyxiation and death.
Use extreme care during installation to provide a tight exhaust system. Terminate exhaust
pipes away from enclosed or sheltered areas, windows, doors, and vents. Do not use exhaust
heat to warm a room, compartment, or storage area.

WARNING
Hot Surface
Hot surfaces can start a fire which can cause severe burns or death.
Use an approved thimble where exhaust pipes pass through wall or partitions.

NOTICE
Weight applied to the engine manifold can result in turbocharger damage. Support the
silencer and exhaust piping so no weight or stress is applied to the engine exhaust elbow.

NOTICE
Gaseous fuels are susceptible to high condensation levels in the exhaust. It is important to
have properly routed/sized exhaust systems to prevent harm to turbochargers and Oxygen
sensors (HEGO).

NOTICE
Liability for injury, death, damage, and warranty expense due to use of unapproved silencers
or modifications to the exhaust system becomes the responsibility of the person installing
the unapproved silencer or performing the modification. Contact your authorized distributor
for approved exhaust system parts.

Pipe exhaust gases to the outside of any enclosure/room. Locate the exhaust outlets away from any
air inlets to avoid gases re-entering the enclosure/room. Exhaust installations are subject to various
detrimental conditions such as extreme heat, infrequent operation, and light loads. Regularly inspect
the exhaust system both visually and audibly to see that the entire system remains fume tight and safe
for operation.

NOTICE
Enclosed generator sets are not generally designed to be used in a building. If the generator
set is to be used in a building, additional requirements must be applied.

Where an enclosed generator set is used in a building, the exhaust system should be extended to
vent the exhaust gases. Use sealed joint type fittings where possible to provide a tight exhaust
system. Use of slip type fittings (secured with a clamp) may allow leakage of exhaust gases into the
building if not fitted correctly. Check to make sure there are no exhaust leaks.

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NOTICE
Flexible pipes must be installed vertically and must be aligned fully with engine and exhaust
tubes. The pipes must not have any bends or curves.

When a unit is provided with a partially installed or incomplete exhaust system, exhaust piping and
chimneys shall be designed, constructed, and installed in accordance with the Standard for the
Installation and Use of Stationary Combustion Engines and Gas Turbines, NFPA 37, or applicable
local standards. Build according to the code requirements in effect at the installation site.
For indoor installation, the exhaust system should use sealed joint type fittings where possible to
provide a tight exhaust system. Use of slip type fittings (secured with a clamp) may allow leakage of
exhaust gases into the building if not fitted correctly fitted. Check to make sure there are no exhaust
leaks.
Use an approved thimble (see Figure 19 on page 46) where exhaust pipes pass through a wall or
partition. Insulated wall/roof thimbles are used where exhaust pipes pass through a combustible roof
or wall. This includes structures, such as wood framing or insulated steel decking, etc. Uninsulated
wall/roof thimbles are used where exhaust pipes pass through a non-combustible wall or roof, such as
concrete. When a unit is provided with a partially installed or incomplete exhaust system, exhaust
piping and chimneys shall be designed, constructed, and installed in accordance with the Standard for
the Installation and Use of Stationary Combustion Engines and Gas Turbines, NFPA 37, or applicable
local standards. Build according to the code requirements in effect at the installation site.
Rain caps are available for the discharge end of vertical exhaust pipes. The rain cap clamps onto the
end of the pipe and opens due to exhaust discharge force from the generator set. When the generator
set is stopped, the rain cap automatically closes, protecting the exhaust system from rain, snow, etc.
Use a section of flexible exhaust pipe between the engine and remainder of exhaust system. Support
the exhaust system to prevent weight from being applied to engine exhaust outlet elbow/turbocharger
connection.
The exhaust system design should meet local code requirements.
Avoid sharp bends by using sweeping, long radius elbows and provide adequate support for the
silencer and tailpipe. Pitch a horizontal run of exhaust pipe downward (away from engine) to allow any
moisture condensation to drain away from the engine. If an exhaust pipe must be turned upward,
install a condensation trap at the point where the rise begins (see Figure 16 on page 44).
Shield or insulate exhaust lines if there is danger of personal contact. Allow at least 305 mm (12
inches) of clearance if the pipes pass close to a combustible wall or partition. Before installing
insulation on exhaust system components, check the exhaust system for leaks while operating the
generator set under full load and correct all leaks.
Refer to T-030, Liquid Cooled Generator Set Application Manual for more detailed information about
sizes of exhaust system pipes and fittings.

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No. Description No. Description

1 Rain Cap 6 Exhaust Pipe Diameter Plus 304 mm (12
Inches)
2 Drip Cap 7 Flashing
3 Holes in End of Inner Sleeve 8 230 mm (9 Inches) Minimum
4 Roof 9 Outside or Dividing Wall
5 230 mm (9 inches) Minimum

FIGURE 15. EXHAUST THIMBLE

FIGURE 16. CONDENSATION TRAP

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No. Description No. Description

1 Exhaust Thimble 4 Water Trap with Drain
2 Support Brackets 5 Muffler
3 Flexible Bellows 6 Exhaust Pipe

The bottom of the muffler is being supported by two mounting brackets with 4 M20 screws under the mounting
brackets used to fix them. Two clamps on the top of the silencer fits with mounting brackets and 4 M20 screws,
nuts, and gaskets. Installation torque for the screw following Q/STB 12.521.5-2000 is required.
FIGURE 17. TYPICAL SUSPENDED EXHAUST SYSTEM

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No. Description No. Description

1 Clamps (Width 80 mm, Thickness 5 mm) 4 M20 x 30 Screw (4)
2 M20 x 30 Screw and nut (4) 5 Mounting Brackets
3 Muffler 6 Waist Holes

FIGURE 18. MUFFLER ASSEMBLY INSTALLATION (4 IN 1)

FIGURE 19. MUFFLER INSTALLATION HOLES (WITH DISTANCE FOR BRACKET INSTALLATION)

7.3 Ventilation and Cooling

WARNING
Toxic Gases
Engine and radiator cooling air may carry carbon monoxide gas, which can cause
asphyxiation and death.
Pipe exhaust gas outside and away from windows, doors, or other inlets to buildings. Do not
allow exhaust gas to accumulate in habitable areas.

Generator sets create considerable heat that must be removed by proper ventilation.
Generator sets in factory-mounted housings for outdoor installation are designed for proper cooling
and ventilation.

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Indoor installations require careful design with respect to cooling and ventilation. In an indoor
installation, all radiator cooling air must be discharged to the out-of-doors. Duct adapter kits are
available.
Outdoor installations normally rely on natural air circulation but indoor installations need properly sized
and positioned vents for required airflow.
Transfer the stray voltage from the cooling system to the ground through the skid.

7.4 Vents and Ducts

1. For indoor installations, locate vents so incoming air passes through the immediate area of the
installation before exhausting. Install the air outlet higher than the air inlet to allow for convection
air movement.
2. Size the vents and ducts so they are large enough to allow the required flow rate of air.
3. Wind will restrict free airflow if it blows directly into the air outlet vent. Locate the outlet vent so
the effects of wind are eliminated, or if the outlet vent cannot be located as mentioned, install a
wind barrier. See Figure 20.

NOTICE
The "free area" of ducts must be as large as the exposed area of the radiator. Refer to
the generator set Specification Sheet for the airflow requirements and allowed airflow
restriction.

No. Description No. Description

1 Prevailing Wind Away from Air Outlet Vent 2 Prevailing Wind Towards Air Outlet Vent, Wind
Barrier Installed

FIGURE 20. WIND BARRIER

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7.5 Dampers
Dampers or louvers protect the generator set and equipment room from the outside environment.
Their operation of opening and closing should be controlled by operation of the generator set.
In cold climates, the radiator exhaust air can be recirculated to modulate the ambient air temperature
in the generator set room. This will help the generator set warm up faster, and help to keep fuel
temperatures higher than the cloud point of the fuel. If recirculation dampers are used, they should be
designed to 'fail closed', with the main exhaust dampers open, so that the generator set can continue
to operate when required. Designers should be aware that the generator set room operating
temperature will be very close to the outdoor temperature, and either not route water piping through
the generator set room, or protect it from freezing.

7.6 Air Inlet and Outlet Openings

Louvers and screens over air inlet and outlet openings restrict air flow and vary widely in performance.
A louver assembly with narrow vanes, for example, tends to be more restrictive than one with wide
vanes. The effective open area specified by the louver or screen manufacturer should be used.
Radiator set cooling air is drawn past the control end of the set by a pusher fan that blows air through
the radiator. Locate the air inlet to the rear of the set. Make the inlet vent opening 1.5 times larger than
the radiator area.
Locate the cooling air outlet directly in front of the radiator and as close as possible. The outlet
opening must be at least as large as the radiator area. Length and shape of the air outlet duct should
offer minimum restriction to airflow.
A flexible duct connector must be provided at the radiator to prevent exhaust air recirculation around
the radiator, to take up generator set movement and vibration, and to prevent transmission of noise.
Attach the flexible duct using screws and nuts so that the duct can be removed for maintenance
purposes. Before installing the duct, remove the radiator core guard.
Enclosed generator sets are primarily designed to work in an open environment. When considering
installing an enclosed generator set in an enclosed environment specific application factors must be
considered (air flow, exhaust gas extraction, fuel supply and storage, etc.). For advice, contact the
Application Engineering Group at Cummins.

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No. Description No. Description

1 Cool Air Inlet Damper 5 Flexible Duct Connector
2 Engine Driven Fan 6 Hot Air Outlet Damper
3 Radiator 7 Distance Should Not be Less Than Height of
Radiator
4 Thermostat Controlled Re-Circulating Damper 8 Wind/Noise Barrier

FIGURE 21. TYPICAL OPEN GENERATOR SET INSTALLATION

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No. Description No. Description

1 Enclosure Air Exhaust 4 Emergency Stop Button
2 Generator Set Lifting 5 External Fuel Connection
Points Opening

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3 Enclosure Lifting Points 6 Power Cable Entry

FIGURE 22.

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8 DC Control Wiring
WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or
death.
Avoid contact with the voltage sense and bus sense leads; voltages of up to 600 VAC may
still be present. These voltages could be live even when the generator set is switched off.

WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or
death.
Make sure all power is off before performing control wire installation.

WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or
death.
To prevent accidental electrocution, stand on a clean dry wooden platform or clean rubber
insulating mat, make sure your clothing and shoes are dry, remove all jewelry, and use tools
with insulated handles.

The generator set control box contains connection points for remote control and monitor options.

NOTICE
Always run control circuit wiring in a separate metal conduit from the AC power cables to
avoid inducing currents that could cause problems within the control.

Use cable ties to keep control wiring away from sharp edges and AC power cables within the control
housing.

NOTICE
Stranded copper wire must be used for all customer connections to the control panel. Solid
copper wire may break due to the generator set vibration.

Use flexible conduit for all wiring connections to the generator set.

8.1 Digital Connections

Connection points, other than relayed outputs and network are considered digital connections. The
type/gauge wire to use for these connections are:
• Less than 305 m (1000 ft), use 0.5 mm2 (20 gauge) stranded copper wire.
• 305 m to 610 m (1000 ft to 2000 ft), use 0.75 mm2 (18 gauge) stranded copper wire.

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8.2 Relay Connections

Due to the wide variety of devices that can be attached to the relay outputs, the electrical contractor
must determine the gauge of the stranded copper wire that is used.

8.3 PowerCommand 3.3 Customer Connections

8.3.1 Configurable Outputs
Each output has normally-open contacts. The contacts can be used to control small devices, indicator
lamps, or relays.
The contacts are programmed to energize by entering a code number for the desired event.

NOTICE
Using the InPower service tool or accessing the Setup submenus is required to modify the
customer outputs. Contact an authorized distributor for assistance.

8.3.1.1 Contact Ratings for Configurable Outputs

TABLE 5. CONTACT RATINGS FOR CONFIGURABLE OUTPUTS

Description Value
Maximum Voltage 30 VDC
Maximum Current 3.5 Amps

8.3.2 Remote Start

WARNING
Automated Machinery
Accidental or remote starting of the generator set can cause severe personal injury or death.
Make sure that the generator set cannot be started accidentally or remotely before starting
work on the generator.

NOTICE
Remote start terminals should only be used for a remote application. Remote start terminals
are not to be shorted if the remote start function is not intended to be used.

When the control is in Auto/Remote mode, grounding this input initiates the engine cranking and start
sequence. This circuit must be opened to permit resetting a shutdown condition with the Reset input.
(The remote stop is actually the removal of the remote start signal to the control.)

8.3.3 Configurable Inputs

Grounding any one of these inputs activates the corresponding warning or shutdown sequence.
External sensing equipment must be connected to the designated digital input.

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

NOTICE
The InPower service tool or access to the Setup submenus is required to modify the
customer fault inputs. Contact your authorized distributor for assistance.

8.3.4 Remote Emergency Stop

Opening this input causes an immediate shutdown. Emergency stop must be reset at the remote
panel, then at the front panel.

8.4 Ground Fault Relays

A Ground Fault Relay (GFR) continuously monitors the neutral-to-ground connection and activates a
fault alarm when the connection is broken. During generator set operation, the relay continuously
monitors the line-to-neutral and activates a fault alarm when a ground fault is sensed.
A control reset will clear the fault at the control panel and will also reset the ground fault relay.

8.4.1 Ground Fault Relay with Local Current Transformer

The ground fault relay with a local Current Transformer (CT) is used on generator sets that have their
neutrals bonded to ground internally in the circuit breaker or entrance enclosure. The ground bonding
jumper is connected between the neutral (L0) bus bar and the equipment grounding bus and passes
through the ground fault sensing CT which drives the GFI relay.

FIGURE 23. GROUND FAULT RELAY USED WITH LOCAL CURRENT TRANSFORMER

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The Ground Fault Relay current transformer is mounted inside the Alternator terminal box. The relay
harness is connected from the relay to the current transformer.

8.4.2 Ground Fault Relay Installation

Refer to the following figure when making wiring connections.

No Description No Description
1 Ground fault Relay 3 A1-A2
2 T1-T2

FIGURE 24. GROUND FAULT RELAY CONNECTIONS

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FIGURE 25. GROUND FAULT RELAY SCHEMATIC

• Ground-fault fixed sensitivities from 30mA to 1A and adjustable sensitivities up to 30A.
• Response from instantaneous (no intentional delay) to 4.5 seconds.
• Outputs may be used for protection via shunt trip of a circuit breaker or switch, or alarming via
lights or annunciator for flexibility.

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9 AC Electrical Connections
WARNING
Arc Flash and Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or
death.
Make sure that only service personnel who are trained and experienced perform electrical
and mechanical component installations. The AC sensing harness and other cabling will
become energized when the generator set is in operation.

WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or death.
Make sure that only personnel who are trained and qualified to work on this equipment are
allowed to operate the generator set and perform maintenance on it.

WARNING
Automated Machinery
Accidental or remote starting of the generator set can cause severe personal injury or death.
Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery
cables (negative [–] first).

WARNING
Combustible Gases
Ignition of battery gases is a fire and explosion hazard which can cause severe personal
injury or death.
Do not smoke, or switch the trouble light ON or OFF near a battery. Touch a grounded metal
surface first before touching batteries to discharge static electricity. Stop the generator set
and disconnect the battery charger before disconnecting battery cables. Using an insulated
wrench, disconnect the negative (–) cable first and reconnect it last.

WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or
death.
Avoid contact with the voltage sense and bus sense leads; voltages of up to 600 VAC may
still be present. These voltages could be live even when the generator set is switched off.

This section provides the procedure that is used to connect the AC electrical system of the generator
set.
Before making any AC electrical connections, make certain the generator set cannot be accidentally
started. Make sure the Operator Panel is in OFF mode. Turn off or remove AC power from the battery
charger and then remove the negative (–) battery cable from the set starting battery using an insulated
wrench.
If the generator set is being installed in an application where it may parallel with other generators or
utility sources, the generator set control system may be energized from an external source. Lock out
tag out any external source that can provide AC power to the generator set.

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NOTICE
Ventilate the battery area before working on or near battery. Wear goggles. Stop the
generator set and disconnect the battery charger before disconnecting battery cables.
Disconnect negative (–) cable first and reconnect last using an insulated wrench.

Connecting the generator set AC electrical system involves:

• Installation of transfer switch
• Installation or verification of paralleling switchboard
• Generator output voltage selection
• Load cable connection
• Standard and optional AC equipment connections (e.g., control box heater, coolant heater, etc.).
For all output connections, including when field connection is made at the alternator terminations,
installation should be completed with conductors of appropriate size, type, and rating specified in local
codes (or UL). For UL compliant installations, use conductor size, X AWG, 75 °C or 90 °C copper
wire, 600V. Where X AWG is the conductor size specified by the local electrical code for 75 °C at the
rated output current for the generator set. Use copper conductors only. For non-UL compliant
installations, use cable sizes, composition, and rating per local codes. Strain relief, bending space,
raceway, and other installation features should be completed in compliance with local code.
Local regulations often require that wiring connections be made by a licensed electrician, and that the
installation be inspected and approved before operation. All connections, wire sizes, materials used,
etc. must conform to the requirements of electrical codes in effect at the installation site.
Before starting the generator set, check to make sure that all electrical connections are secure, and
that all wiring is complete. Replace and secure any access panels that have been removed during
installation. Check that the load cables from the generator set are properly connected.

NOTICE
Backfeed to a utility system can cause electrocution or property damage. Do not connect to
any building electrical system except through an approved device and after the building main
switch is opened.

9.1 Transfer Switch

A transfer switch must be used for switching the load from the normal power source to the generator
set (see Figure 26). Follow the installation instructions provided with the transfer switch when
connecting the load and control wiring.

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No. Description No. Description

1 Normal Power Source 3 Load
2 Overcurrent Protective Device 4 Emergency Power Source

FIGURE 26. TYPICAL LOAD TRANSFER FUNCTION

9.2 Alternator Voltage Connections

These alternators can be configured to the nameplate voltages as shown on the Reconnection
Diagram decal, attached to the backside of the control box cover. Many of the voltages listed will
require reconfiguration of the alternator output leads on the connection terminal block. This
reconfiguration must only be done by service personnel that are trained and experienced to perform
electrical installation. The generator set was adjusted to produce a specified voltage during production
verification testing prior to shipment. The installer must always check the stator lead terminal block
connections and perform any necessary reconnect to obtain the voltage required.
Some generator sets are capable of producing a wide range of voltages and connection
configurations; others have specific limited capabilities. Refer to wiring diagram and generator
voltages (from the nameplate) when reviewing the voltage connection information and use the wiring
diagram supplied with your generator set when actually performing load connections.

NOTICE
Reconfiguring generator sets to higher voltages can exceed the voltage capability of the
specific generator windings and damage the generator and also decrease line current,
rendering line circuit breakers too large. Consult with your authorized distributor before
performing reconnection for a different voltage.

NOTICE
Reconfiguring generator sets to lower voltages can reduce generator set ratings, and also
increase line current, rendering line circuit breakers too small. Consult with your authorized
distributor before performing reconnection for a different voltage.

9.3 Load Connections

NOTICE
Flexible conduit and stranded conductors must be used for connections to take up
movement of the generator set.
Do not change circuit breaker in absence of authorized operator. Connect with your nearest
Cummins Authorized Distributor for genuine Cummins part information.

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All loads are connected to the alternator by bolting stranded load wires to the appropriate terminals on
the alternator reconnection terminal block or circuit breaker lugs. The terminals are marked U, V, W,
and N to indicate the line and neutral connections. (Reference: U, V, and W correspond with L1, L2
and L3; and N with L0 respectively). See Appendix B on page 85 for details about the following:
• Load connections
• Conduit
• Cable Size

9.3.1 Generator Set Load Cable Installation

To ensure optimum performance of the generator set, load cables passing through cable gland plates
must be adequately protected and secured.

9.3.2 Cabling through Non-Ferrous Gland Plates

Single core load cables must be secured using non-ferrous cable glands.

9.3.3 Cabling through Ferrous Gland Plates

Single core load cables must pass through the same hole, or slotted cable gland holes as illustrated
(see Figure 27). Cable glands must be made from non-ferrous material.

No. Description No. Description

1 Cable Gland Holes 2 Slot > 0.5 mm (0.02 in)

FIGURE 27. FERROUS GLAND PLATES

9.3.4 Distribution Cables

Single core power distribution cables should be grouped in a trefoil formation as illustrated (See
Figure 28). (Trefoil grouping provides optimum cable loading and reduces electrical emissions). To
minimize cable temperature rise and reduce cable de-rate factors, cable groups where possible,
should be spaced to provide ventilation. Cable groups must be secured with non-ferrous material.

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FIGURE 28. TREFOIL FORMATION

9.3.5 Enclosure Light

Connect the enclosure lights to a source of power that will be on during the time the engine is not
running. Be sure the supply voltage and circuit amperage is correct it. The customer will have to
arrange the power source for enclosure lights.

9.4 Installation of s-CAN Network Cable

NOTICE
The installation of the s-CAN Network cable is the same for both PCC3300V1 and PCC3300V2
control boards.

The s-CAN cable connects the TB3 of the generator set MLD controller with up to 15 other generator
set MLD controllers to form a closed s-CAN Network.

FIGURE 29. TB3 PINS

TABLE 6. TB3 PIN ASSIGNMENTS: CUSTOMER INPUT/OUTPUT CONNECTIONS

Pin Description Function / Connects to

TB3 - 1 Ground s-CAN shield connection point or use as a
signal return for switch inputs
TB3 - 2 s-CAN Isolated Ground s-CAN network ground only, Do not connect to
chassis/Battery Ground
Connect to TB3-2 of other PCC3300
PC 3.3 MLD ONLY
TB3 - 3 s-CAN CAN L s-CAN data line for control-to-control
communications
Connect to TB3-3 of other PCC3300
PC 3.3 MLD ONLY

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Pin Description Function / Connects to

TB3 - 4 s-CAN CAN H s-CAN data line for control-to-control
communications
Connect to TB3-4 of other PCC3300
PC 3.3 MLD ONLY

TB3-2, TB3-3, and TB3-4 s-CAN Network Connections (PC3.3 MLD ONLY)

FIGURE 30. S-CAN NETWORK DIAGRAM

s-CAN cable requirements: Twisted pair (shielded) cable meets SAE J1939-11 standards, 200 m
maximum network length.

NOTICE
Recommended cable type: Belden 3106A or equivalent.

To prevent ground loops shield/drain wire are to be connected to TB3-1 at only one end of a s-CAN
network (bus) cable/segment. Shield continuity must be maintained over entire length of
cable/segment.

NOTICE
Recommended shield connection method Figure 31

FIGURE 31. SHIELD CONNECTIONS ON MLD S-CAN NETWORK

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9.5 Load Balancing

When connecting loads to the generator set, balance the loads so that the current flow from each line
terminal (L1, L2, and L3) is about the same. This is especially important if both single phase and three
phase loads are connected. Any combination of single phase and three phase loading can be used as
long as each line current is about the same, within 10 percent of median value and no line current
exceeds the name plate rating of the generator. Check the current flow from each line after
connections by observing the Operator Panel ammeter.

9.6 Current Transformers

Current transformers (CTs) reduce high voltage currents (AC) to enable safe monitoring.

9.7 Coolant Heater

The coolant heaters are designed to allow the generator set to start and pick up load within 8.5
seconds in a 4.4 °C (40 °F) environment. In colder ambient temperature environments the starting
time may be longer.

9.7.1 Coolant Heater Connection

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

A coolant heater keeps the engine coolant warm when the engine is shut down. It heats and circulates
the coolant within the engine. This reduces start-up time and lessens engine wear caused by cold
starts. It is electrically operated and thermostatically controlled.
Refer to Appendix C for electrical connections.

9.8 Alternator Heaters

9.8.1 Alternator Heater Connection
WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or
death.
Water or moisture inside an alternator increases the possibility of flashing and electrical
shock. Do not use an alternator which is not dry inside and out.

An alternator heater(s) is used to help keep the alternator free of condensation when the generator set
is not running. During cool and humid conditions, condensation can form within an alternator, creating
flashing and shock hazards.
Connect the heater(s) terminals to a source of power that will be on during the time the engine is not
running. Be sure the supply voltage and circuit amperage is correct for the heater element rating.

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9. AC Electrical Connections 10-2023

9.9 Control Box Heater

9.9.1 Control Box Heater Installation
A thermostat controlled heater is installed inside the control cabinet see Section C.2
The heater power cord must be connected to a grounded outlet.

9.10 Battery Commissioning

NOTICE
Commissioning is to be undertaken by suitably trained and qualified service personnel only.

Lead-acid batteries supplied in dry-charged form are commissioned as follows:

• Pre-Commissioning Procedure
• Filling the Battery with Electrolyte
• Charging
• Fitting the Battery to the Generator Set

9.10.1 Safety Precautions

Servicing of batteries are to be performed or supervised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized personnel away from batteries.

9.10.1.1 General Precautions

WARNING
Combustible Gases
Ignition of battery gases is a fire and explosion hazard which can cause severe personal
injury or death.
Laying tools or metal objects across the battery can cause arcing. Never lay tools or metal
objects across the top of the battery.

CAUTION
Electrical Shock
A battery presents a risk of electrical shock and high short circuit current which can cause
minor or moderate injury.
Observe the following precautions when working on batteries.

• Use proper PPE. Remove jewelry such as watches, rings, or other metal objects. Remove any
conductive items from pockets. These items can fall into equipment and result in a short circuit,
which can cause shock or burning. Refer to local standards for PPE details (in the U.S: see
NFPA 70).
• Keep batteries upright to prevent spillage. Electrolyte is a dilute sulphuric acid that is harmful to
the skin and eyes.
• Use tools with insulated handles to prevent the risk of electric shock.

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9.10.1.2 Fire Hazard

NOTICE
During the charging of a battery, explosive gases are given off. Keep the battery area well
ventilated and away from naked flames and sparks. Do not smoke.

• Before disconnecting a battery, isolate the utility powered battery charger (where fitted).
• To disconnect the battery, use an insulated wrench to disconnect the negative cable first.
• To connect the battery, use an insulated wrench to connect the negative cable last.

9.10.2 Pre-Commissioning Procedure

1. Check for any damage to the battery case or terminals, and make sure that the battery is clean
and dry.
2. Remove the vent plugs and break any seals (if present), taking care not to damage the plates or
separators. The broken seal will fall into the bottom of the chamber and do no harm.

9.10.3 Charging - Commissioning

1. Charge the battery for a minimum of four hours to ensure the acid is sufficiently mixed within the
battery. If the battery has been in storage, check the manufacturer's instructions; the charging
period may need extending.
2. When the generator set is running, check the charge alternator output using an induction
ammeter.

9.10.4 Connecting the Battery to the Generator Set

NOTICE
A battery must not be fitted to a generator set without charge if the specific charge of the
electrolyte has fallen below 1.240 during storage.

1. Secure the battery. Battery hold-down bolts must be tight, but not over-tight.
2. Smear the terminals with petroleum jelly, if necessary.
3. Fit the vents firmly in position and ensure that the battery is clean and dry.
4. Verify correct polarity when connecting the battery to the set. Even momentary incorrect
connection can cause damage to the electrical system.
5. Use an insulated wrench connect the positive generator cable first, followed by the negative
cable. Terminal connections must be tight, but not over-tight.

9.11 Battery Charger

9.11.1 Mains (Utility) Battery Charger - Wall Mounted
Mains (utility) powered battery chargers, which are wall mounted, are available in 5 and 10 amp
ratings, dependent on the generator set configuration. For more information, see the Battery Charger
section of the generator set Operator Manual.

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9.12 Grounding
WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or
death.
Make sure that only service personnel who are trained and experienced perform electrical
and mechanical component installations. Bonding and grounding must be done properly. All
metallic parts that could become energized under abnormal conditions must be properly
grounded.

The following is a brief description of system and equipment grounding of permanently installed AC
generators within a facility wiring system.

NOTICE
It is important to follow the requirements of the local electrical code.

NOTICE
A UL-listed grounding electrode terminal within its ratings and suitable for the application
must be installed and labeled "Grounding Electrode Terminal" for UL compliance.

Figure 32, Figure 33 and Figure 34 illustrate typical system grounding for a 2-pole, 3-pole, and 4-
pole Automatic Transfer Switch (ATS). In the 2-pole and 3-pole ATS, note that the generator neutral is
connected to the ATS and is NOT bonded to ground at the generator. In the 4-pole ATS system, a
grounding electrode conductor and a bonding jumper are used to connect the generator neutral to
ground.
Make sure the generator set is grounded to earth in one location only. On generator sets without a
circuit breaker, ground to the point indicated on the top of the generator. On generator sets with circuit
breakers, use the ground lug provided in the circuit breaker box.
The grounding electrode terminal is not provided. Make sure UL listed terminals are used, are sized
for the generator set ratings, and are suitable for the application.

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No. Description No. Description

1 Service Entrance 3 Generator Set
2 2-Pole ATS 4 Load

FIGURE 32. TYPICAL SYSTEM - ONE-PHASE, THREE WIRE UTILITY, TWO-POLE ATS

No. Description No. Description

1 Service Entrance 3 Generator Set
2 3-Pole ATS 4 Load

FIGURE 33. TYPICAL SYSTEM - THREE-PHASE, FOUR WIRE UTILITY, THREE-POLE ATS

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No. Description No. Description

1 Service Entrance 3 Generator Set
2 4-Pole ATS 4 Load

FIGURE 34. TYPICAL SYSTEM - THREE-PHASE, FOUR WIRE UTILITY, FOUR-POLE ATS

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10 Pre-Start Preparation
WARNING
Electrical Generating Equipment
Incorrect operation and maintenance can result in severe personal injury or death.
Make sure that only suitably trained and experienced service personnel perform electrical
and/or mechanical service.

Before an initial start of the generator set, complete the Installation Checklist, see Chapter 11 on
page 75.

10.1 Initial Pre-Start Checks

WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or
death.
Make sure that only personnel who are trained and experienced work with distribution
voltages. Even after generator set shutdown, an electrical shock hazard may still exist,
caused by induced or residual voltage within the alternator or cables. Some interfaces may
display zero voltage even when voltages are present.

WARNING
Hot Pressurized Liquid
Contact with hot liquid can cause severe burns.
Do not open the pressure cap while the engine is running. Let the engine cool down before
removing the cap. Turn the cap slowly and do not open it fully until the pressure has been
relieved.

Before starting, competent personnel must make the following checks to make sure that the unit is
ready for operation:

TABLE 7. INITIAL PRE-START CHECKS

Check Description

Generator Set Grounding (earthing) must be checked prior to performing service or inspection procedures
that may expose personnel to conductors normally energized with voltages greater than 600
Grounding Volts. Contact your authorized Cummins distributor.
This must be performed on all generator sets before initial start-up and after the generator
Insulation set grounding procedure has been completed. Insulation testing for low voltage (less than
600 Volts) generator sets is recommended by Cummins. These tests are used to verify that
Testing1 the windings are dry before the generator set is operated, and to develop a base line for
future test comparisons. Contact your authorized Cummins distributor.
Lubrication2 Check the engine lubrication oil level and ensure that the correct level is always maintained.
Check the engine coolant level and ensure that the level is always maintained. Fill the
Coolant3,4,5 cooling system to the bottom of the fill neck in the radiator fill or expansion tank. Do not
check the level while the engine is hot.

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Check Description
1
When wire insulation-testing an alternator, failure to protect the voltage regulator, control and diodes could result
in permanent damage to one or more of the electronic components.
2
Generator sets shipped dry only: They must be filled with the correct type and quantity of oil before use. Be sure
to check the oil level before initial start. Failure to fill to the recommended level can result in equipment damage.
3
Generator sets that require a mix of anti-freeze and DCA inhibitor only: You must comply with Cummins
requirements for the correct type and concentration of anti-freeze and DCA inhibitor. Warranty claims for damage
will be rejected if the incorrect mix is used. Consult your authorized Cummins distributor for the correct anti-freeze
specifications and concentration for your operating conditions.
4
Radiators with two fill necks only: Both fill necks must be filled after the cooling system has been drained.
5
Generator sets shipped dry only: The engine must be filled with the correct type and quantity of coolant before
use. Be sure to check coolant level(s), before the initial start.

10.2 Electrical System

Verify all electrical connections are secure and all wiring is complete and inspected. Replace and
secure any access panels that may have been removed during installation.

10.3 Battery Connections

WARNING
Automated Machinery
Accidental or remote starting of the generator set can cause severe personal injury or death.
Make sure that the generator set cannot be started accidentally or remotely before starting
work on the generator.

WARNING
Combustible Gases
Ignition of battery gases is a fire and explosion hazard which can cause severe personal
injury or death.
Do not smoke, or switch the trouble light ON or OFF near a battery. Touch a grounded metal
surface first before touching batteries to discharge static electricity. Stop the generator set
and disconnect the battery charger before disconnecting battery cables. Using an insulated
wrench, disconnect the negative (–) cable first and reconnect it last.

Starting the unit requires one or more batteries. For more information on batteries, refer to the Model
Specifications section. To prevent arcing, use an insulated wrench to connect the positive battery
cable, then connect the negative battery cable.
If an automatic transfer switch is installed without a built-in charge circuit, connect a separate battery
charger. Proper selection and maintenance of batteries and battery chargers is essential for system
reliability.

10.4 Site-Specific Configuration

NOTICE
Site-specific configuration is to be undertaken by suitably trained and qualified service
personnel only.

The generator set is configured at the factory. Before starting the generator set, any site-specific
configuration should be completed by qualified service personnel.

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10.5 Starting
Refer to the generator set Operator manual for important safety precautions and recommended
procedures for starting the generator set and verifying proper operation. Start the generator set and
verify all engine and generator set menus are displaying the correct values.

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11 Installation Checklist
11.1 Checklist
Tick General Items
Generator set output is sufficient to handle maximum anticipated load.
At least 0.9 m (3 feet) of clearance (or greater for housing door) is provided around the entire generator
set for service and ventilation.
The generator set is located in an area not subject to flooding.
All operating personnel have read and are familiar with the generator set Operator manual, all health and
safety procedures, warnings, cautions, precautions, and the other documentation supplied with the
generator set.
All operators have been thoroughly briefed on preventative maintenance procedures.
All operators have read and understand all important safety instructions.
Any parts requiring software have been checked for the latest version. Contact the service representative
for more information.
Generator Set Position
The floor, roof, or earth on which the generator set rests is strong enough and will not allow shifting or
movement. Observe local codes on soil bearing capacity due to freezing and thawing.
The generator set is properly supported and retained to an approved base.
The supporting base is large enough and is of non-combustible material, extending 15 cm (6 inches) all
around the generator set.
Provisions have been made for site specific environmental operating conditions (weather protection,
proximity to coastline, dusty environments, etc.,)
Cooling Air Flow
Generator set air inlet is faced into the direction of strongest, prevailing winds.
Air inlet openings are unrestricted and are at least 1 to 11/2 times larger than air outlet area.
Cooling air outlet is on downwind side of building (if not, a wind barrier is constructed).
Proper ducting material (sheet metal, canvas) is used between radiator and air outlet.
Diesel Fuel System (if applicable)
Fuel tanks meet or exceed all local, State, or National codes (if applicable).
Fuel lines are properly installed, supported, and protected against damage.
The fuel filters have been installed.
Approved flexible fuel line is installed between the main fuel supply and the generator set’s fuel system
near the generator set, to protect it against damage caused by vibration, expansion, and contraction.
Strainer or fuel screen (100 to 200 mesh) is installed in the fuel supply line to protect the fuel lift pump,
day tank transfer pump, or float valve seat from fuel tank debris (if applicable).
The fuel filter assembly shipped with the generator set is installed and operational (if applicable).
Fuel supply shutoff valves are installed to prevent fuel flow in case of leaks.
No shutoff valves are installed on engine fuel return line (if applicable).

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11. Installation Checklist 10-2023

Tick General Items

External fuel pumps are connected and operational at all times - generator set started or shut down (if
applicable).
Fuel tanks are filled with the correct grade / type of fuel (if applicable).
Fuel system is properly primed.
No fuel leaks are found in supply line or engine fuel system.
Gaseous Fuel System (if applicable)
Check fuel line and use equations to verify it has proper volume capability.
Check if fuel pressure is between 7-13 inches water column.
Check for any gas leaks.
If necessary, perform initial demand regulator adjustment procedure.
Make sure fuel pressure does not drop below 7 inches water column under full load.
Exhaust System
The breather tube routing is set up to blow the fumes away from the generator set (if applicable)
Operators are thoroughly briefed on the dangers of carbon monoxide gas.
If the installation includes a heavy duty air cleaner, it has been installed.
Areas around generator set are well ventilated, with no possibility of exhaust fumes entering building
doors, windows, or intake fans.
Exhaust gases are piped safely outside and away from building.
The correct length of approved rigid pipe is connected to the generator set flexible pipe using approved
securing methods with no weight resting on engine exhaust components. There are no bends in flex
section.
Condensation drain is provided in lowest section of exhaust piping.
Exhaust piping is insulated to guard against burns to personnel.
Exhaust piping passing through walls or ceilings have approved fire-proof materials and are in
compliance with all codes.
Exhaust piping is large enough in diameter to prevent excessive back pressure on engine.
Verify that the pyrometer meters are functioning.
AC and DC Wiring
For bottom entry circuit breaker installations, the cable chute has been installed (if applicable).
Wire sizes, insulation, conduits and connection methods all meet applicable codes.
AC and DC wires are separated in their own conduit to prevent electrical induction.
All load, line and generator connections are well made and correct.
Flexible conduit is used between the generator and the building or surrounding structure.
Check phase rotation.
Generator Set Pre-Start
Generator set engine is properly serviced with oil and coolant.
Battery charger is installed using the appropriate cable size and is operational.
Battery charger is configured for the proper DC battery voltage, battery type, and float voltage.
Batteries are properly installed, serviced and charged.

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Tick General Items

Battery temperature sensor is connected and operational (if applicable).
Cooling system is filled with correct volume and concentration of coolant. The water used in the coolant
mix has passed water quality check.
Engine coolant heater is connected and operational.
All generator set covers and safety shields are installed correctly.
All fuel and coolant shutoff valves are operational.
Shipping skid, brackets, and pads have been removed.
Radiator fan and other external moving parts, including drive belts, are unrestricted.

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12 Manufacturing Facilities
U.S. and CANADA EMEA, CIS BRAZIL
Cummins Inc. Cummins Inc. Rua Jati, 310, Cumbica
1400 73rd Ave. NE Royal Oak Way South Guarulhos, SP 07180-900
Minneapolis, MN 55432 USA Daventry CNPJ: 43.2201.151/0001-10
Northamptonshire Brazil
NN11 8NU
United Kingdom
Toll Free 1-800-CUMMINSTM Phone +44 1327 88-6453 Phone 0800 286 6467
(1-800-286-6467) Fax +44 1327 88-6125
Fax +1 763-574-5298

CHINA INDIA ASIA PACIFIC

Cummins Inc. Cummins Inc. Cummins Sales and Service
No.118 South Quanli Road , Plot No B-2, SEZ Industrial Area, Singapore Pte Ltd
Wuhan Economic& Technological Village-Nandal & Surwadi, Taluka- 85 Tuas South Avenue 1
Development Zone , Hubei, Phaltan Singapore 637419
P.R.China 430058 Dist- Satara, Maharashtra 415523
India
Phone + 86 (27) 8421 4008 Fax +65 6265 6909
Phone +91 021 66305514
Fax + 86 (27) 8421 4804

LATIN AMERICA MEXICO

3350 Southwest 148th Ave. Eje 122 No. 200 Zona Industrial
Suite 205 San Luis Potosi, S.L.P. 78395
Miramar, FL 33027 Mexico
USA
Phone +1 954 431 551 Phone +52 444 870 6700
Fax +1 954 433 5797 Fax +52 444 824 0082

12.1 How to Obtain Service

When a product requires servicing, contact the nearest Cummins service provider. To locate the
distributor, go to www.cummins.com/support and select Find a Sales or Service Location. When
contacting the service provider, always supply the complete model, specification, and serial number as
shown on the nameplate.

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12. Manufacturing Facilities 10-2023

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Copyright © 2023 Cummins Inc. 80 A045E599 (Issue 5)

Appendix A. Alternator Reconnect
Drawing

Table of Contents
Figure 35. Reconnect Drawing for HC Alternator (Sheet 1) ............................................................... 83
Figure 36. Reconnect Drawing for HC Alternator (Sheet 2) ............................................................... 84

A045E599 (Issue 5) 81 Copyright © 2023 Cummins Inc.

Appendix A. Alternator Reconnect Drawing 10-2023

The drawings included in this section are representative. For current complete
information, refer to the drawing package that was shipped with the unit.

Copyright © 2023 Cummins Inc. 82 A045E599 (Issue 5)

10-2023 Appendix A. Alternator Reconnect Drawing

A.1 0625-3100 Reconnect Drawing for HC Alternator

FIGURE 35. RECONNECT DRAWING FOR HC ALTERNATOR (SHEET 1)

A045E599 (Issue 5) 83 Copyright © 2023 Cummins Inc.

Appendix A. Alternator Reconnect Drawing 10-2023

FIGURE 36. RECONNECT DRAWING FOR HC ALTERNATOR (SHEET 2)

Copyright © 2023 Cummins Inc. 84 A045E599 (Issue 5)

Appendix B. Outline Drawings

Table of Contents
Figure 37. Sheet 1 of 2 ........................................................................................................................... 87
Figure 38. Sheet 2 of 2 ........................................................................................................................... 88
Figure 39. Sheet 1 of 3 ........................................................................................................................... 89
Figure 40. Sheet 2 of 3 ........................................................................................................................... 90
Figure 41. Sheet 3 of 3 ........................................................................................................................... 91
Figure 42. Sheet 1 of 2 ........................................................................................................................... 92
Figure 43. Sheet 2 of 2 ........................................................................................................................... 93

A045E599 (Issue 5) 85 Copyright © 2023 Cummins Inc.

Appendix B. Outline Drawings 10-2023

The drawings included in this section are representative. For current complete
information, refer to the drawing package that was shipped with the unit.

Copyright © 2023 Cummins Inc. 86 A045E599 (Issue 5)

10-2023 Appendix B. Outline Drawings

B.1 A051A703 Outline Drawing (For IBC and CSA)

FIGURE 37. SHEET 1 OF 2

A045E599 (Issue 5) 87 Copyright © 2023 Cummins Inc.

Appendix B. Outline Drawings 10-2023

FIGURE 38. SHEET 2 OF 2

Copyright © 2023 Cummins Inc. 88 A045E599 (Issue 5)

10-2023 Appendix B. Outline Drawings

B.2 A064F343 Outline Drawing (Enclosed Genset)

FIGURE 39. SHEET 1 OF 3

A045E599 (Issue 5) 89 Copyright © 2023 Cummins Inc.

Appendix B. Outline Drawings 10-2023

FIGURE 40. SHEET 2 OF 3

Copyright © 2023 Cummins Inc. 90 A045E599 (Issue 5)

10-2023 Appendix B. Outline Drawings

FIGURE 41. SHEET 3 OF 3

A045E599 (Issue 5) 91 Copyright © 2023 Cummins Inc.

Appendix B. Outline Drawings 10-2023

B.3 A066H639 Outline Drawing (Open Genset)

FIGURE 42. SHEET 1 OF 2

Copyright © 2023 Cummins Inc. 92 A045E599 (Issue 5)

10-2023 Appendix B. Outline Drawings

FIGURE 43. SHEET 2 OF 2

A045E599 (Issue 5) 93 Copyright © 2023 Cummins Inc.

Appendix B. Outline Drawings 10-2023

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Appendix C. Wiring Diagrams

Table of Contents
Figure 44. A050R932 Wiring Diagram (Sheet 1 of 13) ........................................................................ 97
Figure 45. A050R932 Wiring Diagram (Sheet 2 of 13) ........................................................................ 98
Figure 46. A050R932 Wiring Diagram (Sheet 3 of 13) ........................................................................ 99
Figure 47. A050R932 Wiring Diagram (Sheet 4 of 13) ...................................................................... 100
Figure 48. A050R932 Wiring Diagram (Sheet 5 of 13) ...................................................................... 101
Figure 49. A050R932 Wiring Diagram (Sheet 6 of 13) ...................................................................... 102
Figure 50. A050R932 Wiring Diagram (Sheet 7 of 13) ...................................................................... 103
Figure 51. A050R932 Wiring Diagram (Sheet 8 of 13) ...................................................................... 104
Figure 52. A050R932 Wiring Diagram (Sheet 9 of 13) ...................................................................... 105
Figure 53. A050R932 Wiring Diagram (Sheet 10 of 13) .................................................................... 106
Figure 54. A050R932 Wiring Diagram (Sheet 11 of 13) .................................................................... 107
Figure 55. A050R932 Wiring Diagram (Sheet 12 of 13) .................................................................... 108
Figure 56. A050R932 Wiring Diagram (Sheet 13 of 13) .................................................................... 109
Figure 57. Sheet 1 of 2 ......................................................................................................................... 110
Figure 58. Sheet 2 of 2 ......................................................................................................................... 111
Figure 59. Sheet 1 of 1 ......................................................................................................................... 112
Figure 60. Sheet 1 of 1 ......................................................................................................................... 113
Figure 61. Sheet 1 of 1 ......................................................................................................................... 114
Figure 62. Sheet 1 of 1 ......................................................................................................................... 115
Figure 63. Sheet 1 of 1 ......................................................................................................................... 116
Figure 64. Sheet 1 of 1 ......................................................................................................................... 117

A045E599 (Issue 5) 95 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

The drawings included in this section are representative. For current complete
information, refer to the drawing package that was shipped with the unit.

Copyright © 2023 Cummins Inc. 96 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

C.1 A050R932 Wiring Diagram with PowerCommand 3.3 Control

FIGURE 44. A050R932 WIRING DIAGRAM (SHEET 1 OF 13)

A045E599 (Issue 5) 97 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

FIGURE 45. A050R932 WIRING DIAGRAM (SHEET 2 OF 13)

Copyright © 2023 Cummins Inc. 98 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

FIGURE 46. A050R932 WIRING DIAGRAM (SHEET 3 OF 13)

A045E599 (Issue 5) 99 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

FIGURE 47. A050R932 WIRING DIAGRAM (SHEET 4 OF 13)

Copyright © 2023 Cummins Inc. 100 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

FIGURE 48. A050R932 WIRING DIAGRAM (SHEET 5 OF 13)

A045E599 (Issue 5) 101 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

FIGURE 49. A050R932 WIRING DIAGRAM (SHEET 6 OF 13)

Copyright © 2023 Cummins Inc. 102 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

FIGURE 50. A050R932 WIRING DIAGRAM (SHEET 7 OF 13)

A045E599 (Issue 5) 103 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

FIGURE 51. A050R932 WIRING DIAGRAM (SHEET 8 OF 13)

Copyright © 2023 Cummins Inc. 104 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

FIGURE 52. A050R932 WIRING DIAGRAM (SHEET 9 OF 13)

A045E599 (Issue 5) 105 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

FIGURE 53. A050R932 WIRING DIAGRAM (SHEET 10 OF 13)

Copyright © 2023 Cummins Inc. 106 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

FIGURE 54. A050R932 WIRING DIAGRAM (SHEET 11 OF 13)

A045E599 (Issue 5) 107 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

FIGURE 55. A050R932 WIRING DIAGRAM (SHEET 12 OF 13)

Copyright © 2023 Cummins Inc. 108 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

FIGURE 56. A050R932 WIRING DIAGRAM (SHEET 13 OF 13)

A045E599 (Issue 5) 109 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

C.2 A051C423 Control Box Heater Wiring Diagram with PowerCommand 3.3 Control

FIGURE 57. SHEET 1 OF 2

Copyright © 2023 Cummins Inc. 110 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

FIGURE 58. SHEET 2 OF 2

A045E599 (Issue 5) 111 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

C.3 0625-3100 Wiring Diagram- Generator Reconnect

FIGURE 59. SHEET 1 OF 1

Copyright © 2023 Cummins Inc. 112 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

C.4 0630-2727 Wiring Diagram- Control

FIGURE 60. SHEET 1 OF 1

A045E599 (Issue 5) 113 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

C.5 0630-3216 Wiring Diagram- Control

FIGURE 61. SHEET 1 OF 1

Copyright © 2023 Cummins Inc. 114 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

C.6 0630-3217 Wiring Diagram- Schematics

FIGURE 62. SHEET 1 OF 1

A045E599 (Issue 5) 115 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

C.7 0630-2934 Wiring Diagram- Schematics

FIGURE 63. SHEET 1 OF 1

Copyright © 2023 Cummins Inc. 116 A045E599 (Issue 5)

10-2023 Appendix C. Wiring Diagrams

C.8 0630-2935 Wiring Diagram- Schematics

FIGURE 64. SHEET 1 OF 1

A045E599 (Issue 5) 117 Copyright © 2023 Cummins Inc.

Appendix C. Wiring Diagrams 10-2023

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Copyright © 2023 Cummins Inc. All rights reserved.
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Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.