CUMMINS QST30 - Page 84

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5-2

CUSTOMER

INTERFACE

A34

ENGINE INTERFACE

A31

ANALOG BOARD

A33

DIGITAL BOARD

A32

DISPLAY BOARD

A35

RUN/OFF/AUTO

SWITCH S12

S5 POWER ON/

STANDBY SWITCH

GOVERNOR

OUTPUT MODULE

A38

PT/CT

BOARD A36

VOLTAGE

REGULATOR

OUTPUT MODULE

A37

FIGURE 5-1. CIRCUIT BOARD LOCATIONS

Main Page

Table of Contents3
Important Safety Instructions7
Exhaust Gases Are Deadly7
Fuel and Fumes Are Flammable7
General Safety Precautions8
Containerized Rental Units Potential Tipping Problem8
Jack Stands at Nose of Container9
Introduction11
Test Equipment11
How to Obtain Service11
System Overview12
Generator Set Control Function12
Generator Set Control Functions12
Control Operation13
General13
Safety Considerations13
Pcc Power On/Standby Mode13
Front Panel14
Display Menu Selection Switches15
Self Test Switch15
Panel Lights Switch15
Phase Selector Switch and Indicators15
Digital Display and Menu Selection Switches16
Menu Display and Switches16
Main Menu16
Engine Menu18
OIL/COOLANT Submenu18
BATTERY/HOURS Submenu18
RPM/EXHAUST Submenu18
Engine19
Gen Menu20
VOLTS/AMPS Submenu20
Gen21
Circuit Boards and Modules23
Circuit Board Locations23
Block Diagram24
Digital Board25
Switch25
Leds25
Connectors25
Engine Interface Board (A31)26
Fuses26
DS10 GOV Duty Cycle26
Engine Interface Board27
Analog Board (A33)28
Digital Display Board (A35)29
Customer Interface Board (A34)30
Customer Interface Board31
Pt/Ct Board (A36)32
Voltage Regulator Output Module33
Governor Output Module (A38)34
Troubleshooting35
Status Indicators36
Resetting the Control36
Warning and Shutdown Codes37
Pcc Oil Pressure Warning & Shutdown Limits45
Troubleshooting Procedure46
Engine Does Not Crank—Local or Remote Run48
High Engine Temperature Warning (211) or Shutdown60
Low Coolant Warning or Shutdown61
Mag Pickup Shutdown62
Overspeed Shutdown63
DC (Battery) Warnings64
Low Fuel −Day Warning65
Low Fuel Warning66
Eeprom Error Shutdown (250) or Warning67
Rack Position Warning68
Customer Faults69
High Ac Voltage Shutdown70
Low Ac Voltage Shutdown73
Under Frequency Shutdown75
Overcurrent Warning (320) or Shutdown76
Short Circuit Shutdown76
Overload Warning76
Troubleshooting Analog Signals between Analog and Digital Boards77
Pcc Fuses80
Rack Position Fault/Test Procedure81
Control Service and Calibration83
Circuit Board Removal/Replacement83
Control Panel Recalibration83
Circuit Board Removal Safety Precautions85
Wrist Strap85
Initial Start Setup Menu86
Initial Start Setup87
Adjust Menu88
VOLTAGE Submenu88
FREQUENCY Submenu88
START DELAY Submenu88
Setup and Calibration Menus90
ENTER CODE Submenu90
Version and Displays Menus90
Version & Displays Menus91
DISPLAYS Submenus92
SAVE/EXIT Submenu92
Meters Menu94
Governor/Regulator Menu96
Setup Menu98
Setup Defaults98
SETUP Submenu98
TORQUE ADJ %DC Submenu98
Calibration Procedure102
Voltage and Frequency Adjustment102
Digital Voltage Display Calibration102
Digital Ammeter Display Calibration103
Digital Power Factor Display Calibration103
Digital Coolant Temperature Display Calibration103
Analog Meter Calibration103
Engine Torque Adjustment104
Accessory Box Control Components104
Accessory Box Components105
+TB1 Customer Inputs106
TB1 Customer Outputs106
Run Relays (K11, K12, K13)107
Optional Run Relays107
Alarm Relay (K14)108
Optional Alarm Relay108
RTD Relay (Optional)109
Temperature Relay Connections109
Thermistor Relay (Optional)110
Engine Sensors111
Engine Sensor Locations112
Magnetic Speed Pickup Unit (Mpu) Installation113
Mpu Sensor113
Current Transformer (Ct) Installation114
CT Installation Requirements114
Digital Board (A32) Calibration115
Digital Box116
Servicing the Alternator117
Typical Alternator117
Alternator/Pcc Control Isolation Procedure118
Testing the Alternator119
Insulation Resistance Testing119
Alternator Insulation Resistance119
Drying the Windings120
Exciter Stator121
Testing the Exciter Stator121
Winding Resistance Values121
Exciter Rectifier Bridge (Rotating Rectifier Assembly)122
Testing Diodes122
Replacing Diodes122
Surge Suppresser Testing and Replacement122
Exciter Rotor123
Testing Winding Resistance123
Testing Winding Insulation Resistance123
Testing the Exciter Rotor123
Main Rotor (Alternator Field)124
Insulation Resistance and PI Test124
Testing the Main Rotor124
Main Stator125
Testing Main Stator Winding Resistance125
Testing the Alternator Stator125
Testing the Pmg126
Bearing Inspection127
Bearing Removal127
P7 Bearing Removal127
P7 Bearing Replacement127
HC6 Bearing Removal128
HC6 Bearing Replacement128
HC6 Bearing Lubrication128
Alternator Disassembly129
Permanent Magnet (PMG) Removal129
Permanent Magnet (PMG) Installation129
Hc6 Alternator and Control Housing Assembly130
P7 Alternator and Control Housing Assembly130
Main Stator and Rotor Removal131
Removing Control Housing132
Hc6 Alternator Lifting Positions133
P7 Lifting Position134
Removing Hc6 Stator Assembly135
Removing P7 Stator Assembly136
Typical Alternator Assembly138
Alternator Assembly Removal139
Alternator Reassembly140
Aligning Alternator with Engine143
Angular Misalignment143
Axial Misalignment143
Misalignment Symptoms143
Angular Alignment Procedure144
Angular Alignment Measurement144
Sample Alternator Runout Readings145
Angular Alignment Measurement Readings145
HC6 Axial Alignment Procedure146
Hc6 Axial Alignment Measurement146
P7 Axial Alignment Procedure147
Optional Enclosure Fuel Tank System149
Wiring Connections149
Fuel Transfer Control Customer Outputs149
PCC Customer Inputs149
Fuel Transfer Pump150
Control Panel Switches and Indicators150
Switches150
Indicators150
Transfer Pump Control Front Panel151
External/Internal Alarm Panels152
Overfill Indicator/Horn/Silence Button152
Fuel Gauge152
Test Button152
Rupture Basin Leak Detect Switch Test153
Rupture Basin Leak Detect Switch153
Wiring Diagrams155
Generators157

CUMMINS QST30 - Page 84

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