Cummins Power Command Control 3200 Series Generator Sets Official Service Repair Manual
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This is the COMPLETE Official Service Repair Manual .
This manual contains deep information about maintaining, assembly, disassembly and servicing your Cummins.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
Models And Serials :
PowerCommand Control 3200 Series Generator Sets
Models DQKH
CONTENTS :
IMPORTANT SAFETY INSTRUCTIONS . ..iii
1 INTRODUCTION
About this Manual . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . 1-1
How To Obtain Service . . . . . . . . . . . . . . . . . 1-1
2 CONTROL OPERATION . . . . . . . . . . . . . .2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Sequence of Operation . . . . . . . . . . . . . . . . .2-1
Control Panel Power On/Off Modes . . . . . .2-1
Control Panel Assembly . . . . . . . . . . . . . . . .2-4
Reading Fault Codes . . . . . . . . . . . . . . . . . . .2-6
Menu Display and Switches . . . . . . . . . . . . .2-7
Menu Units Selection . . . . . . . . . . . . . . . . . .2-8
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Engine Submenus . . . . . . . . . . . . . . . . . . . . .2-11
Alternator Submenus . . . . . . . . . . . . . . . . . 2-12
Control Submenu . . . . . . . . . . . . . . . . . . . . .2-13
History/About Submenus . . . . . . . . . . . . . .2-14
Bus Data Submenu . . . . . . . . . . . . . . . . . . . 2-16
Power Transfer Main/Submenus . . . . . . . . 2-17
Utility (PWR TRAN) Submenus) . . . . . . . . . 2-19
Status (PWR TRAN) Submenus) . . . . . . . . . 2-20
Transfer Control (PWR TRAN) Submenu) . .2-21
Genset (PWR TRAN) Submenus) . . . . . . . . .2-22
3 CONTROL CALIBRATION AND ADJUSTMENT
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Modifying Setup/Adjust Submenus . . . . . . 3-1
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Governing/Volt Reg Submenu . . . . . . . . . . .3-4
Customer Faults Submenus . . . . . . . . . . . . . 3-5
Calibration Submenus . . . . . . . . . . . . . . . . . .3-6
Isolated Bus/Utility Submenus (Paralleling Application) . . . 3-7
Isolated Bus Submenus . . . . . . . . . . . . . . . . 3-8
Utility Submenus . . . . . . . . . . . . . . . . . . . . . . 3-11
Power Transfer Control Main Menus . . . . . 3-12
Utility Sensors Submenus . . . . . . . . . . . . . . .3-13
Genset Sensors Submenus . . . . . . . . . . . . . .3-15
Timers Submenu . . . . . . . . . . . . . . . . . . . . . . .3-17
Test/Exercise Submenu . . . . . . . . . . . . . . . . . 3-18
Adjust Submenu . . . . . . . . . . . . . . . . . . . . . . .3-19
Calibration Procedure . . . . . . . . . . . . . . . . . . 3-20
Control Box Wiring . . . . . . . . . . . . . . . . . . . . .3-22
Run Relays (K11, K12, K13) . . . . . . . . . . . . . . .3-24
Alarm Relay (K16) . . . . . . . . . . . . . . . . . . . . . . 3-25
Magnetic Speed Pickup Unit (MPU) Installation . . . .3-26
4 SERVICING THE GENERATOR
Testing the Generator . . . . . . . . . . . . . . . . . . . 4-1
Insulation Resistance (Megger) & Polarization Index (PI) Testing . . . 4-2
Drying the Windings . . . . . . . . . . . . . . . . . . . . 4-4
Generator/PCC Control Isolation Procedure .4-5
Exciter Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Exciter Rectifier Bridge (Rotating Rectifier Assembly) . . 4-7
Exciter Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Main Rotor (Generator Field) . . . . . . . . . . . . . . 4-9
Main Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Testing the PMG . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
P7 Bearing Inspection/Removal . . . . . . . . . . . . 4-14
P7 Generator Disassembly/Reassembly . . . . . .4-15
P80 Bearing Inspection/Removal . . . . . . . . . . . .4-22
P80 Generator Disassembly/Reassembly . . . . .4-24
Aligning Generator with Engine . . . . . . . . . . . . 4-28
5 WIRING DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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