Manual Partes Kta-38
Manual Partes Kta-38
Generator Set
KTA38G4/G5/G14 Engine with PowerCommand 3.3
Control and PowerCommand 3.3 MLD Control
C900 D6B
C1000 D5B
C1000 D6B
C1100 D5B
English
Original Instructions 10-2021 A035B002 (Issue 10)
Publication A035B002 Parts Manual
Issue 10 − 10-2021 Model: C900 D6B − C1100 D5B
Table of Contents
Description Page
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Quick Serve Online (QSOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Paint and Thread Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Low Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Coolant Heater (240 V) cont. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sump Drain Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Generator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Generator Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Oil Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Control Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Control Cabinet Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Control Box Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Entrance Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Current Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Safety Precautions
The following symbols are used in Cummins manuals to alert users to the potentially dangerous conditions
relating to maintenance of equipment and replacement of parts. Please read and observe.
This symbol warns of immediate hazards which will result in severe personal injury or
death.
This symbol refers to a hazard or unsafe practice which can result in severe personal
injury or death.
This symbol refers to a hazard or unsafe practice which can result in severe personal in-
jury or product or property damage.
Improper operation and maintenance can lead to severe personal injury or loss of life
and property by fire, electrocution, mechanical breakdown or exhaust gas asphyxiation.
Read and follow all safety precautions in the health and safety manual 0908−0110.
Contact with USED ENGINE OILS has been identified by a United States federal agency
and some USA state agencies as causing CANCER or REPRODUCTIVE TOXICITY. When
checking or changing engine oils take all necessary precautions not to ingest, breathe
the fumes or contact the used oil.
Contact with ASBESTOS has been identified by a United States federal agency and
some USA state agencies as causing CANCER or REPRODUCTIVE TOXICITY. When
handling engine gaskets take all necessary precautions not to ingest, breathe or contact
the dust from the gaskets! Use adequate ventilation and wear protective gloves, masks
and clothing!
Contact with BENZINE and LEAD, found in gasoline, fuel additives and solvents has
been identified by a United States federal agency and some USA state agencies as caus-
ing CANCER or REPRODUCTIVE TOXICITY. When checking, draining or adding gaso-
line and fuel additives or using solvents take all necessary precautions not to ingest,
breathe the fumes or contact the liquids. Use adequate ventilation and wear protective
gloves, masks and protective clothing!
* − The diagonal line (/) in the model and specification number separates generator set characteristics from the
specification number and letter. The specification number denotes customer requested options or deviations from the
standard model. The specification letter advances (A to B, B to C, etc.) with major manufacturing changes.
# − 380−13,800V (Refer to Genset Data Sheet).
Related Literature
The related literature that is appropriate to your generator set includes:
Operator Manual for KTA38−G4/G5 with PC 3.3 (A048A216)
Installation Manual for KTA38−G4/G5 with PC 3.3 (A050V074)
Operator Manual for KTA38−G14 with PC 3.3 (A035A999)
Installation Manual for KTA38−G14 with PC 3.3 (A035B000)
Generator Set Service Manual for KTA38 with PC 3.3 or 3.3 MLD Control (A035B001)
Controller Service Manual for PC 3.3 (0900−0670)
Engine Operation & Maintenance Manual for KTA38 (3810497)
Alternator Service Manual for HC Alternators (0900−9914)
Specification and Data Sheet (For engineeringt data specific to the generator set)
Application Manual T−030, Liquid Cooled Generator Sets (For application information)
Standard Repair Times − CL Family (0900−0913)
Recommended Spares List (RSL) for KTA38−G4/G5 − C1000 D6B & C1000 D6B (Spec E−F)
(A035B508)
Recommended Spares List (RSL) for KTA38−G4/G5 − C1100 D5B & C1100 D5B (Spec E−F)
(A035B503)
Recommended Spares List (RSL) for KTA38−G14 − C900 D6B & C900 D6B (Spec E−F) (A049U148)
Recommended Spares List (RSL) for KTA38−G14 − C1000 D5B & C1000 D5B (Spec E−F) (A049V183)
Recommended Spares List (RSL) for KTA38−G14 − C1100 D5B & C1100 D5B (Spec E−F) (A050V068)
Recommended Spares List (RSL) for KTA38−G14 − C1000 D6B & C1000 D6B (Spec E−F) (A050V069)
Warranty Manual (F1117−0002)
Global Commercial Warranty Statement (A028U870)
Model Identification
This manual covers generator set models produced under the Cummins brand name.
To avoid errors or delay in filling your parts order, always state the MODEL and SERIAL NUMBER from the
Cummins nameplate.
The engine serial number is located on a data tag on the engine or is stamped on the engine block.
The control software number is located on the electronic control module (ECM) or can be obtained via the
digital interface if one is available.
For reference document your generator set information in the spaces below.
Abbreviations
Some of the following abbreviations may be used throughout this Parts Manual:
AC Alternating Current LED Light−Emitting Diode
ACB Air Circuit Breaker LTP Limited Time Power Rating
ACH Anti−Condensations Heaters LTA Low Temperature Aftercooling
ATS Automatic Transfer Switch LV Low Voltage
Amp Ampere
M Meter
A/R As Required
MCB Miniature Circuit Breaker
AVR Automatic Voltage Regulator
MCCB Moulded Case Circuit Breaker
AWG American Wire Gauge
MF Mains Failed
BHP Brake Horsepower MFSS Master First Start Sensor
BMS Building Measurement System mm Millimeter
BST Busnar Sensing Transformer MOH Mobile Off Highway
MR Mains Returned
CAN Controlled Area Network
MST Mains Sensing Transformer
CB Circuit Breaker
MSU Mains Sensing Unit
CCA Cold Cranking Amps
MV Medium Voltage
CHP Combined Heat and Power
COP Continuous Power Rating NEC Neutral Earthing Contact
CT Current Transformer NFS Not For Sale
dB(A) Unit of noise level NPT National Pipe Thread
DC Direct Current OD Outside Diameter
Deg Degree oz. Ounce
DIP Dual In−line Package
DMC Digital Master Control PC PowerCommand 3.3
DMSU Demand Load Standby Unit PC Printed Circuit
PF Power Factor
ECM Engine Control Module Ph Phase
EFC Electronic Fuel Control PFC Power Factor Controller
EIT External/Internal Tooth PLC Programmable Logic Controller
EMCU Engine Monitoring and Control Unit PMG Permanent Magnet Generator
EMF Electromotive Force PRP Prime Power Rating
EPROM Erasable Programmable Read PSU Power Supply Unit
Only Memory PT/CT Potential Transformer/Current
EPU Engine Protection Unit Transformer
ET External Tooth PTC Power Transfer Control
FAE Full Authority Engine QCC Quadrature Current Control
FSS First Start Sensor
RFI Radio Frequency Interference
GCP Generator Control Panel RMS Root Mean Square
GFI Ground Fault Interrupter RPM Revolutions Per Minute
GKWT Global Kilowatt Transducer RT Right
HMI Human/Machine Interface RTD Resistance Temperature Detector
HV High Voltage Spec Specification
IC Integrated Circuit Thk Thick
ID Inside Diameter
IEC International Electrotechnical UL Underwriters Laboratories Inc.
Commission UNC Union National Coarse
I/O Input / Output UNF Union National Fine
IT Internal Tooth V Volts
kVA Apparent Power VAC Volts, Alternating Current
kVAR Reactive Power VCB Vacuum Circuit Breaker
kW Active / Real Power (Kilowatt) VDC Volts, Direct Current
kWh Unit of electrical energy or work VF Volt−free
VT Voltage Transformer
LPG Liquid Petroleum Gas
LT Left W/(ET, IT, EIT) With
Labels
1 2 3 4 5
6 7 8 9 10
11 13 14
12
15 17
16
Labels
Consumables
The following is a list of consumables associated with the generator models covered in this manual:
Service Consumables
Ref.
Page No. Part No. Description Qty
21 0503−2386 Hose, Coolant 1
46 0501290 Line, Fuel − Supply 1
46 0501291 Line, Fuel − Return 1
Engine
Engine Accessories
Radiator Tap
Air Cleaner
Air Cleaner
1
3
2, 7
9 1
1
4
5
6
8
2
8
2
7 4
6
1
5
12
13
10
11
16
8 2 11
6 12
6 12 14
7 10 15
9
Radiator − 40
7 12 13
11 5
10
4
1
15
3
14 2
9
8
15 3 12
4
5
15
8 11
6 10 14
2 13
7 9
Radiator − 50
4
21
15
24 8 7 16
14
23
13
11
17 6
5 18
22
1
12 2
25 19 10
20
Radiator − 50
Generator
Generator − HC634 (1 Bearing, 4 Pole)
5
7 2
4 3 21 18
20
9
6 19 17
8 20
10 27 25 22
28
26
29
14
12
11
15
22
13
16
31 24
23
29
30
Generator
Generator − HC634 (2 Bearing, 4 Pole)
5
7 21
3 2
4 18
9 10
17
1
6 27 20 22
25
19 26
8 13 14
28
12
32
34 11
35 33
15
31
29 16
30
24 23
Generator Heater
Generator Fasteners
3
4
5 1
2
Terminal Box
6
1 5
4
2
3
8 9
17
16
15
10
11
9
12 8
13
14
6
5
1 4
2
3
13 12
14 13
17
16
15
7 14
8 13
9
10
11
6
5
1 4
2
3
7
8
8
14
14
9 8
10
11
12
13
Skid
8
15 9
7 16 4 10
8 17
9 18
10 14 6
13 19
12
11
2
5
9
10 9
3
5
9
10
Battery
Fuel Lines
2 1
Oil Container
3
4
5
Control
15
24
11
1
5 20
13
4
21
22
23
16
17
18
19
14
2
6
8
9 12
10
11
Control
Control (Continued)
10
4 17 5 17 6 18 7 16 8 9 20 19 1 14 13 11 12 15
22
3 21
21
Control Harness
3 1
6 2
Control Mounting
3 2
Control Cabinet
10 4
21 18
20 2 19
11
12 9
13
14
1
15
16 3
5
6
7
17
Control Cabinet
Control Box
3 1
2 3 4 7 8 1
5 5
6 6
9 9
4
5
1 2
1
2
Engine Harness
4
5
6
2
Controller Box 3
AC Harness (PMG)
DC Harness
Junction Box
3
4
Common Alarm
Run Relay
1
2
Parallel Relay
Audible Alarm
7 3 1
4
5
3
2
1
6 5 4 3 2
7
8
Ground Fault
6
8 7 10
12
11
5
4
3 1
2
Pyrometer
3
4
Level Switch
1 2
Battery Charger
1 2
Entrance Box
5
6
2
1
Circuit Breaker
Accessories
15
16 20
3 17 21
1
2 18 22
8
19
7
14
4
5
9 10 11 12 13
L1 L2 L3 N
15 20
16
3 17 1 21
22
2 18 8
19
7
14
4
5
9 10 11 12 13
L1 L2 L3 N
Neutral Bar
3
4
5
2
6
3
5
10 10
11 13
13 14
14 2 3
6
7
8
9
15
16
4 17
18
10 5
12
13
14
19 20
1
10
11
13
14
3
4
6
7 15
8 16
9 17
18
12
7 13
9 4
10 6
5 3
1
11
4
6
5
13
2 7
9
10
10
9
7
8
1
10
4
6
5
2
11
7
8
9
11
2
8
9
7
10
A Section A−A
4
B
1
11
2
8
9
7
10
B Section B−B
11 13
1
5
7
4 6
3
12
14
Switchgear Leads
1
8
3 4 5
2
Current Transformer
Silencer
2 1 2
3 4
9
17
22
23
25 24
1 27 25
28 28
29
5
19
10
26
6
7
16
17
18 16
17
13 18
8
12
14 16
17
18
5 7 1
Topical Index
A Bush, Spacer, 20
Index (Continued)
F Heater, Generator, 35
Heater, Support, 19
Fan, Radiator, 27 Holder, Fuse, 52 , 71
Fastener, Generator, 36 Hose, 22
Fuse, 71 Hose, Coolant, 20 , 21
Fuse, Cartridge, 52 Hose, Radiator, 23 , 25 , 27
Hose, Vent, 27
Hub, Radiator, 27
G
Gasket, 57 I
Gasket, Fuel Tank, 95
Isolator, Vibration, 57
Gasket, Radiator, 24 , 27
Gauge, Level, 95
J
Generator − 1 Bearing (HC634), 29
Jumper, Terminal, 52
Generator − 2 Bearing (HC634), 33
Grommet, Remote, 57
Ground Fault, 72
K
Guard, Radiator, 24 , 27 Kit, Air Filter, 15 , 17
Kit, Bearing, 27
Kit, Complete PMG Upfit , 29 , 33
H Kit, Coolant Heater, 19
Harness, AC (PMG), 63
Harness, Accessory, 65 , 68 , 71 , 72 , 77 L
Harness, Alarm, 66 Label Warning, 19
Harness, Alternating Current, 53 , 89 Labels, 9
Harness, Circuit Breaker, 89 Lead, Earth, 85 , 86
Harness, Control, 53 Lead, Electrical, 69
Harness, DC, 63 Lead, Ground, 51 , 57 , 81 , 82 , 83 , 84
Index (Continued)
R Spreader, Terminal, 81 , 82
Stator, Exciter, 29 , 33
Radiator, 23 , 25
Strap, Electrical, 57
Radiator − 40 Deg., 24
Strap, Ground, 72
Radiator − 50 Deg., 27
Strip, Marker, 52
Rail, Terminal, 52
Switch, Level, 74 , 95
Rail, Terminal Block, 72 , 89
Switch, Pushbutton, 59
Rail, Terminal Box, 39 , 41 , 43
Switch, SPDT, 77 , 89
Relay, 52 , 72 Switch, Temperature − Low Engine Coolant, 12
Relay, Control, 66 , 67 , 68 , 89
Relay, Ground Fault, 72
Relay, Parallel, 68
T
Relay, Power, 51 Tank, Fuel, 95
Relay, Run, 67 Tank, Radiator, 24
Relay, Temperature, 71 Tap, Radiator, 13
Ring, Locking, 64 , 65 Tap, Sump Drain, 22
Rod, Battery Hold Down, 44 Timer, 71
Rotor, Exciter, 29 , 33 Transformer, Current, 72 , 92
Tray, Battery, 44
Trip, Shunt, 72 , 90
S Trip, Under Voltage, 89
Seal Rectangular Ring, 19 Tube Heater , 19
Selant Thread, 19 Tube, Radiator, 24
Sender, Exhaust Gas Temperature, 73 Tube, Water, 27
Index (Continued)
V Valve, Ball, 22
Numerical Index
Part No. Page Part No. Page Part No. Page Part No. Page