Operator Manual Generator Set for Home Standby C13N6H (Spec B) C17N6H (Spec B) C20N6H (Spec B) C20N6HC (Spec B) English Original Instructions 8-2019 A062J680 (Issue 2)
Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1.2 General Information ................................................................................................................ 1.3 Generator Set Safety Code ..............................................................................................
Table of Contents 8-2019 5.8 Complete System Test ........................................................................................................ 83 6. TROUBLESHOOTING ................................................................................................................. 6.1 Avoiding Generator Set Shutdowns ..................................................................................... 6.2 Troubleshooting With the Local Display ...................................................
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. IMPORTANT SAFETY INSTRUCTIONS 8-2019 General Safety Precautions 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.
8-2019 1. IMPORTANT SAFETY INSTRUCTIONS 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 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.
1. IMPORTANT SAFETY INSTRUCTIONS 8-2019 WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. The generator set must be off and locked out of service whenever the air inlet, air outlet, or any interior panels are removed. WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death.
8-2019 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. 1.4 Moving Parts Can Cause Severe Personal Injury or Death • Keep hands, clothing, and jewelry away from moving parts.
1. IMPORTANT SAFETY INSTRUCTIONS 8-2019 • 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 because copper will become brittle if continuously vibrated or repeatedly bent. • Be sure all fuel supplies have a positive shutoff valve. • Be sure the battery area has been well-ventilated prior to servicing near it.
8-2019 1. IMPORTANT SAFETY INSTRUCTIONS WARNING Combustible Gases Batteries can explode, causing severe skin and eye burns, and can release toxic electrolytes. Do not dispose of the battery in a fire, because it is capable of exploding. Do not open or mutilate the battery. Do not charge frozen batteries. WARNING Electric Shock Hazard Batteries present the risk of high short circuit current. When servicing the generator set: • Remove watches, rings, or other metal objects.
1. IMPORTANT SAFETY INSTRUCTIONS 8-2019 • Make sure the unit is well ventilated. 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.
8-2019 1.9 1. IMPORTANT SAFETY INSTRUCTIONS The Hazards of Carbon Monoxide Carbon monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas. You cannot see it or smell it. Red blood cells, however, have a greater affinity for CO than for oxygen. Therefore, exposure even to low levels of CO for a prolonged period can lead to asphyxiation (lack of oxygen) resulting in death.
1. IMPORTANT SAFETY INSTRUCTIONS 8-2019 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. Copyright © 2019 Cummins Inc.
2 Introduction 2.1 Safety 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.
2. Introduction 8-2019 NOTICE This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions: • This device may not cause harmful interferences. • This device must accept any interference received, including interference that may cause undesired operation. 2.3 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.
8-2019 2. Introduction Abbr. Description Abbr.
2. Introduction 8-2019 Abbr. 2.4 Description LCD Liquid Crystal Display LCT Low Coolant Temperature Abbr. UPS Description Uninterruptible Power Supply 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 familiarize themselves with the warnings and operating procedures. NOTICE A generator set must be operated and maintained properly if you are to expect safe and reliable operation.
8-2019 2. Introduction • Warranty Failure Code Manual (F1115C) • Engineering Application Manual T-030: Liquid Cooled Generator Sets (A040S369) 2.5 Model Specifications TABLE 1. MODEL VARIATIONS Model Natural Gas or Propane Vapor kW Amps C13N6H Both 13 54.2 C17N6H Both 17 70.8 Natural Gas Only 18 75 Propane Vapor Only 20 83.3 C20N6H, C20N6HC Frequency Voltage 60 Hz 120/240 VAC Single Phase NOTICE Maximum load imbalance allowed is 50% of generator set rating. TABLE 2.
2. Introduction 8-2019 C13N6H Type scfh C20N6H, C20N6HC C17N6H BTU/hr scfh BTU/hr scfh BTU/hr Fuel Pressure kPa in water column Note: Maximum pressure for either fuel under any condition: 3.2 kPa (13 inch water column) TABLE 4. ENGINE SPECIFICATIONS Type Value Engine 2 cylinder v-twin, OHV, air-cooled, 4-stroke, spark ignited Displacement 999 cc (60.9 in3) Spark Plug Gap 0.38–0.58 mm (0.015–0.023 in) Spark Plug Torque (Cold Engine) 25–30 Nm (18–22 ft-lb) Magneto Gap 0.25–0.
8-2019 2. Introduction TABLE 6. GENERATOR SET WET WEIGHT (INCLUDING BATTERY) Model Value C13N6H 218 kg (479 lb) C17N6H, C20N6H, C20N6HC 241 kg (531 lb) TABLE 7. GENERATOR SET DERATING GUIDELINES Engine Power Available Up To... Model Derate At… Elevation Ambient Temperature C13N6H 2100 m (6900 ft) 25 °C (77 °F) C17N6H 300 m (1000 ft) 25 °C (77 °F) C20N6H, C20N6HC 0 m (0 ft) 15 °C (60 °F) Elevation Temperature 3.5% per 300 m (1000 ft) 1% per 5.
2. Introduction 8-2019 TABLE 10. DC SYSTEM SPECIFICATIONS Type Value Nominal Battery Voltage 12 VDC Battery Group 51 R Battery Type Lead Acid Minimum Cold Crank Amps (CCA) 2.6 450 After Sales Services Cummins offers a full range of maintenance and warranty services. Maintenance WARNING Electrical Generating Equipment Incorrect service or parts replacement can result in severe personal injury, death, and/or equipment damage.
8-2019 2. Introduction How to Obtain Service For parts, service, and product information, contact the nearest authorized Cummins dealer. To easily locate the nearest certified distributor/dealer for Cummins generator sets in your area, or for more information, contact us at 1-800CUMMINSTM (1-800-286-6467) or visit www.cummins.com/support.
2. Introduction 8-2019 Manufacturing Facilities Facility U.S. and CANADA Address Phone Numbers Toll Free 1-800-CUMMINSTM (1-800-286-6467) Phone +1 763-574-5000 Fax +1 763-574-5298 Cummins Inc. 1400 73rd Ave. NE Minneapolis, MN 55432 USA EMEA, CIS Cummins Inc. Columbus Avenue Manston Park Manston, Ramsgate Kent CT12 5BF United Kingdom ----------Cummins Inc. Royal Oak Way South Daventry Northamptonshire NN11 8NU United Kingdom Phone +44 1843 255000 Fax +44 1843 255902 ASIA PACIFIC Cummins Inc.
8-2019 Facility MEXICO 2. Introduction Address Eje 122 No. 200 Zona Industrial San Luis Potosi, S.L.P. 78395 Mexico A062J680 (Issue 2) Phone Numbers Phone +52 444 870 6700 Fax +52 444 824 0082 21 Copyright © 2019 Cummins Inc.
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3 Control System 3.1 System Setup "Establishing Communications" Message NOTICE Once the battery is connected to the generator set and any display button is pressed, the local display shows an "establishing communications" message for approximately 5 seconds. (This may take longer if the signal integrity is poor between the control and display due to a bad wire or Electro-Magnetic Interference [EMI].) Once communication is established, the display shows the HOME screen.
3. Control System 8-2019 FIGURE 1. HINGE LOCATION "Clock Setup" Screen NOTICE The Clock needs to be reset whenever the battery power is lost or disconnected, or the control has entered “sleep” mode. Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power. The 30minute timer is reset with any button press on the display. NOTICE The optional Remote Monitoring System (RMS) uses the generator set's clock.
8-2019 3. Control System To set up the generator set clock for the current date and time: 1. From the Main screen, select Menu. 2. Use the arrow keys to highlight Clock. Select the Enter key. 3. Use the arrow keys to set the time and date. A062J680 (Issue 2) 25 Copyright © 2019 Cummins Inc.
3. Control System 8-2019 FIGURE 2. CLOCK SETUP SCREEN 4. Select the Next key to go to the Daylight Savings screen. Copyright © 2019 Cummins Inc.
8-2019 3. Control System 5. Use the arrow keys to enable/disable Daylight Savings. If enabling, select the Next key to highlight the Offset field. FIGURE 3. DAYLIGHT SAVINGS TIME (ENABLED) 6. Use the arrow keys and Next key to set the offset value for Daylight Savings time. A062J680 (Issue 2) 27 Copyright © 2019 Cummins Inc.
3. Control System 8-2019 FIGURE 4. OFFSET VALUE 7. Select the Next key to go the screen that is used to set up when Daylight Savings should start. Use the arrow keys and Next key to set Month (1 – 12), Week (0 – 5), Day (Sun – Sat) and Hour (12AM – 12PM). Copyright © 2019 Cummins Inc.
8-2019 3. Control System FIGURE 5. DAYLIGHT SAVINGS TIME (START TIME SETUP) 8. Select the Next key to go the screen that is used to set up when Daylight Savings should end. Use the arrow keys and Next key to set Month (1 – 12), Week (0 – 5), Day (Sun – Sat) and Hour (12AM – 12PM). A062J680 (Issue 2) 29 Copyright © 2019 Cummins Inc.
3. Control System 8-2019 FIGURE 6. DAYLIGHT SAVINGS TIME (END TIME SETUP) 9. Keep selecting the Back button to save the settings and return to the main screen. Copyright © 2019 Cummins Inc.
8-2019 3. Control System "Exercise" Screen When installing an RA series transfer switch, follow these steps to configure the Exercise mode in the generator set's local display or remote display. NOTICE Exercise settings need to be reset whenever battery power is lost or disconnected, or the control has entered “sleep” mode. NOTICE Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power.
3. Control System 8-2019 • Bimonthly: will exercise the generator set on the first and third occurrence of the selected day every month • Monthly: will exercise the generator set on the first occurrence of the selected day every month • Never: will never exercise the generator set Select the Next key to go to the date and time fields. 6. Use the arrow keys to set the day and time the generator set will be exercised. Select the Next key to highlight the Exercise Now field. 7.
8-2019 3. Control System FIGURE 7. A062J680 (Issue 2) EXERCISE SETUP SCREEN 33 Copyright © 2019 Cummins Inc.
3. Control System 8-2019 "Brightness and Contrast" Screen To adjust the brightness and contrast of the display: 1. From the Main screen, select Menu. 2. Use the arrow keys to highlight Display Setup. Select the Enter key. 3. Use the arrow keys to set brightness and contrast for the display. 4. Keep selecting the Back button to save the settings and return to the Main screen. Copyright © 2019 Cummins Inc.
8-2019 3. Control System FIGURE 8. A062J680 (Issue 2) BRIGHTNESS AND CONTRAST SCREEN 35 Copyright © 2019 Cummins Inc.
3. Control System 8-2019 "Mode" Screen When Remote is set to Enabled via the local display, the “Remote On” LED on the front of the display will illuminate indicating that the control will accept start commands from remote displays or remote monitoring systems including a web page or cell phone app. NOTICE The Remote function can only be activated (that is, enabled) from the local display.
8-2019 3. Control System FIGURE 9. MODE SETUP SCREEN (LOCAL DISPLAY) 2. To enable or disable the Standby mode on the REMOTE display: NOTICE Remote must be enabled before Standby mode can be changed from the Remote display. If Remote mode is not enabled, Standby will remain disabled and cannot be changed. a. From any screen, select the Mode key to get to the Mode screen. b. Use the arrow keys to enable or disable the Standby mode. c.
3. Control System 8-2019 Remote Monitoring System (RMS) Description Introduction The Remote Monitoring System (RMS) feature allows for in-home or remote access to your generator set through a web page or smart phone app. Using the RMS, you can start or stop the generator set, adjust the exerciser date and time, determine if utility power is available, and view the last 20 events and/or faults on the generator set.
8-2019 3. Control System NOTICE The following Internet browsers are compatible with this option: • Microsoft Internet Explorer® (version 9 or greater) • Apple Safari® • Google Chrome™ • Mozilla Firefox® (version 3.6 or greater) • Microsoft® Edge RMS Customer Account Setup and Generator Set Control Connection The following instructions for setting up an account and the generator set control connection are for customers only. 1.
3. Control System 8-2019 FIGURE 11. Copyright © 2019 Cummins Inc.
8-2019 3. Control System FIGURE 12. ETHERNET PORT ON GENERATOR CONTROL 5. The ethernet cable needs to be rated for 300V if it is routed through the same conduit as the AC load cables. 6. From the control, verify that your generator set has cloud connectivity on the Cloud Info screen on the display by pressing Menu => Next => About => Next => Next. 7. From a computer device, access the Cummins ConnectCloud website by navigating to https://connectcloud.cummins.com/. 8.
3. Control System 8-2019 10. Click on the Accept button. 11. Enter your email address. Click the Send Verification Code button. 12. Check your email for the verification code and enter it in the Verification code field. 13. Click the Verify Code button. 14. Create a new password. 15. Enter your first name and last name. 16. Click on the Create button. 17. Complete the required (*) fields on the Setup New Generator page: a. Enter the contact information for the location. b.
8-2019 3.2 3. Control System Generator Set Status "About" Screen To retrieve information about the display: 1. From the Main screen, select Menu. 2. Use the arrow keys to highlight About. Select the Enter key. A062J680 (Issue 2) 43 Copyright © 2019 Cummins Inc.
3. Control System 8-2019 FIGURE 13. Copyright © 2019 Cummins Inc.
8-2019 3. Control System "Event Log" Screen To retrieve information from the Event Log: 1. From the Main screen, select Menu. 2. Use the arrow keys to highlight Event Log. Select the Enter key. 3. Use the arrow keys to navigate through the Event Log. 4. Keep pressing the Back button to return to the Main screen. FIGURE 14. EVENT LOG SCREEN "Fault Log" Screen To retrieve information from the Fault Log: 1. From the Main screen, select Menu. A062J680 (Issue 2) 45 Copyright © 2019 Cummins Inc.
3. Control System 8-2019 2. Use the arrow keys to highlight Fault Log. Select the Enter key. 3. Scroll through the fault log using the up and down double-arrows. Each screen provides a brief description of the fault, the fault code number, the engine hours and the time and date of the fault. NOTICE If there are no faults recorded, the “No Stored Faults" screen will appear. 4. Keep pressing the Back button to return to the Main screen. FIGURE 15. Copyright © 2019 Cummins Inc.
8-2019 3. Control System "System Status" Screen To retrieve system status: 1. From the Main screen, select Menu. 2. Use the arrow keys to highlight System Status. Select the Enter key. 3. Keep pressing the Back button to return to the Main screen. FIGURE 16. A062J680 (Issue 2) SYSTEM STATUS SCREEN 47 Copyright © 2019 Cummins Inc.
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4 Operation 4.1 Safety Considerations 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.
4. Operation 8-2019 NOTICE Ventilate the battery area before working on or near the battery. Wear goggles. Stop the generator set and disconnect the battery charger before disconnecting the battery cables using an insulated wrench. Disconnect the negative (–) cable first and reconnect it last. All maintenance tasks must be assessed for health and safety risks; the preventive measures identified must be performed.
8-2019 4. Operation Cummins does not know how you will use your generator set. The equipment owner and operator, therefore, is responsible for safe operation in the installation site environment. Consult your authorized Cummins service provider for further information. Sequence of Operation NOTICE The following sequences are based on an approximate time duration. Your generator set may vary slightly from the timing diagrams in this manual. All referenced times are based on default control settings.
4. Operation 8-2019 FIGURE 18. GENSET STARTING 2. After the generator set reaches rated voltage and frequency, the transfer switch transfers the building load to the generator set. The building's electrical power is now provided by the generator set. FIGURE 19. GENSET POWER 3. When utility power is restored, the sequence to transfer building load to the utility begins. 4. The generator set continues to run and waits for utility power to stabilize. Copyright © 2019 Cummins Inc.
8-2019 4. Operation FIGURE 20. UTILITY RE-TRANS 5. When utility power is stable for 5 minutes, the transfer switch connects the building load back to utility power. FIGURE 21. UTILITY RETURNED 6. The generator set runs an additional 5 minutes to cool down and then shuts off. FIGURE 22. ENGINE COOLDOWN 7. Normal operation resumes. See Figure 17. Exercise Sequences 1. Standard Exercise sequence: NOTICE Standby Mode must be enabled for standard exercise to execute.
4. Operation 8-2019 NOTICE While the generator set is exercising, the building load remains connected to the utility; it is not transferred to the generator set. The following steps will be executed when the programmed exercise day and time are reached or the Exercise Now option is selected and the standard exercise sequence is run: a. The generator set starts. FIGURE 23. EXERCISE CYCLE STARTED b. After the generator set reaches rated speed and voltage, the exercise timer is started.
8-2019 4. Operation FIGURE 24. EXERCISING c. When the defined exercise time has completed, the generator set stops and normal operation resumes. FIGURE 25. EXERCISE CYCLE COMPLETED 2. Crank Only Exercise Sequence NOTICE Standby Mode must be enabled for Crank Exercise to execute. When Crank Exercise is enabled, the generator set will alternate between crank only exercise and standard (that is, generator set running) exercise sequences.
4. Operation 8-2019 b. The generator set engine starter cranks for 8 seconds, rests for 15 seconds, and cranks another 8 seconds if the generator set control has not verified the information it is monitoring. Depending on the outcome of this sequence, either a shutdown fault message is issued or normal standby operation resumes. FIGURE 26. 4.
8-2019 4. Operation 4. After the generator set reaches rated voltage and frequency, the transfer switch transfers the building load to the generator set (unless the circuit breaker on the generator set is "off"). The building's electrical power is now provided by the generator set. FIGURE 27. 4.6 GENSET POWER Manual Stop Sequence (Local) The following steps will be executed when Manual Stop is selected at the Local display: 1. Press the red STOP button on the local display.
4. Operation 8-2019 If a generator set fault occurs that will stop the generator set, the red FAULT light illuminates and a Fault message appears. The screen shows the Fault Code (FC) number, a brief description of the fault, current engine hours and the time and date of the fault. FIGURE 28. TYPICAL FAULT SCREEN Press the BACK button to reset the fault and return to the home screen. The red FAULT light will shut off.
8-2019 4. Operation FIGURE 31. AUTO STOP – UTILITY RETURNED FIGURE 32. FIGURE 33. EXERCISE CYCLE STARTED EXERCISE CYCLE COMPLETED 2. Maintenance and Service Events: NOTICE When a maintenance or service event occurs, the New Event screen will display and the display's yellow service light will turn on. A062J680 (Issue 2) 59 Copyright © 2019 Cummins Inc.
4. Operation 8-2019 NOTICE Refer to the Periodic Maintenance Schedule section for more information. FIGURE 34. SCHEDULED MAINTENANCE REMINDER EXAMPLE FIGURE 35. LOW BATTERY VOLTAGE WARNING FIGURE 36. LOW OIL LEVEL WARNING Press the BACK button to return to the home screen and turn off the light (if lit). See the "Event Log" Screen section of this manual for instructions on viewing the list of the last 20 events. 4.
8-2019 4. Operation When the generator set is started automatically in Standby mode due to a loss of utility or manually by the operator, the control will energize all four load management outputs, disconnecting the associated loads from AC power. Once the transfer switch transfers to generator set power, the generator set control will evaluate the total load on the generator set versus a set point programmed into the control (80% of rated).
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5 Maintenance 5.1 Maintenance Safety 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 Hydrogen Gas Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury or death.
5. Maintenance 8-2019 WARNING Access Using the generator set or part of as a means of access when attaching lifting shackles, chains, or other lifting aids, may damage the generator set, causing severe personal injury or death. Do not use the generator set as a means of access. Failure to follow these instructions can result in severe personal injury or death. WARNING Exposed Terminations Some panel internal components may have live exposed terminations even if the generator set is not running.
8-2019 5. Maintenance To immobilize the generator set: 1. Press the generator set's red STOP button on the local display to stop the generator set. Allow the generator set to thoroughly cool to the touch. 2. Thoroughly ventilate the generator set before disconnecting any leads. 3. Turn off and disconnect any AC powered devices at the generator set, such as oil heater, battery heater, and battery charger before disconnecting the battery cables. 4.
5. Maintenance 8-2019 Repair or replace worn, damaged, or improperly functioning components identified during periodic maintenance procedures. Periodic Maintenance Guidelines Regularly performing the following periodic maintenance tasks greatly reduces the chances of a generator set shutdown: • Maintain an appropriate oil level. • Keep battery connections clean and tight. • Do not overload the generator set. • Keep the air inlet and outlet openings clear.
8-2019 5. Maintenance TABLE 11. MAINTENANCE FREQUENCY Maintenance Frequency Maintenance Task First 25 Hours and 100 Hours Every 24 Hours Every 24 Every 200 Hours or Hours 6 Months Every 2 Years ■2, 3 Check Engine Oil Level Change Engine Oil and Oil Filter ■ ■4 Adjust Engine Valve Clearance ■1, 6 ■1, 6 Replace Engine Air Filter ■4 Clean and Check Starting Battery ■ ■4 ■4 ■7 Clean Slip Rings ■5, 6 Complete System Test ■5, 6 1. 2. 3. 4. 5. 6.
5. Maintenance Date 8-2019 Engine Hours Meter Reading Maintenance or Service Performed Record the name, address, and phone number of your authorized Cummins service center: Name Address Phone Exercising the Generator Set NOTICE Audible engine RPM variation may be heard when there is no load applied. This is normal and does not affect the generator set performance. Exercising the generator set drives off moisture, relubricates the engine, and removes oxides from electrical contacts.
8-2019 5. Maintenance The generator set exerciser mode defaults are as follows. • Day: Tuesday • Time: 2:00 pm • Period: Monthly • Run Time: 5 minutes Refer to the Exercise Settings section of this manual for more information on setting up the exerciser. Maintenance Procedures - Daily or When Refueling Monitor fluid levels, oil pressure, and coolant temperature frequently. During operation, be alert for mechanical problems that could create unsafe or hazardous conditions.
5. Maintenance 8-2019 • Unusual engine noise • Excessive use of coolant, fuel or lubricating oil • Any coolant, fuel, or lubricating oil leaks • Misfire • Unexplained frequency fluctuation • Significant vibration • Excessive white and/or black exhaust smoke. 5.3 Engine Oil Recommended Engine Oil Check the oil level prior to starting the generator set to verify that the oil level is between the High and Low marks. The generator set is shipped with 0W30 synthetic engine oil.
8-2019 5. Maintenance NOTICE Overfilling can cause foaming or aeration of the oil, and operation below the low mark may cause loss of oil pressure. Do not operate the generator set with the oil level below the low mark or above the high mark. No. Description No. Description 1 Engine Oil Level Dipstick 4 Engine Oil Drain Hose 2 Engine Oil Fill 5 Battery 3 Engine Oil Filter FIGURE 37. A062J680 (Issue 2) ENGINE OIL COMPONENTS (SIDE VIEW) 71 Copyright © 2019 Cummins Inc.
5. Maintenance No. 1 8-2019 Description No. Engine Oil Level Dipstick FIGURE 38. 2 Description Engine Oil Fill ENGINE OIL COMPONENTS (TOP VIEW) To check the engine oil level: 1. Make sure that the generator set has not been running for approximately five minutes. 2. Clean off the area surrounding the dipstick port and prevent debris from entering the engine. 3. Pull out the dipstick and wipe it clean. 4. Reinsert and fully seat the dipstick. 5. Remove the dipstick and check the oil level. 6.
8-2019 5. Maintenance Adding or Draining Oil WARNING Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE when working on hot equipment and avoid physical contact with hot surfaces. WARNING Hot Engines Contact with hot engines can cause severe burns. Ensure that the generator set engine has cooled down before adding or draining the oil. NOTICE Too much oil can cause high oil consumption. Too little oil can cause severe engine damage.
5. Maintenance 8-2019 5. When a sufficient amount of oil has been drained from the system, close the drain valve at the engine and the oil drain cap on the hose. 6. Wipe the oil drain cap clean. 7. Re-install the access panels. Torque the fasteners 5.0–6.6 Nm (3.5–5.0 ft-lb). 8. Dispose of the used oil in accordance with local and state regulations. Changing Engine Oil and Oil Filter NOTICE Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death.
8-2019 5. Maintenance 4. Make sure the generator set is shut down and disabled: a. Press the generator set's "O" (Off) button to stop the generator set. Allow the generator set to thoroughly cool to the touch. b. Turn off and disconnect the battery charger from the AC source before disconnecting the battery cables. c. Disconnect the negative (–) cable from the battery and secure it from contacting the battery terminals to prevent accidental starting. d.
5. Maintenance 8-2019 20. Reconnect the cables and battery charger: a. Reconnect the engine battery cables, positive (+) cable first. b. Reconnect the battery charger to its AC power source. 21. Reconnect the oil heater AC power or energize its AC circuit. 22. Operate the generator set with no load for approximately 5 minutes to check for leaks at the oil filter or oil drain hose. 23. Shut down the generator set, wait 5 minutes, and then confirm that the correct oil level is in the pan. 24.
8-2019 5. Maintenance No. 1 Description No. Air Cleaner Housing FIGURE 39. 2 Description M6 Pan Head Screws AIR CLEANER ELEMENT WITH PAN HEAD SCREWS 5. Remove the top of the air cleaner housing which contains the air cleaner element. Ensure that no debris is allowed to enter the base of the air cleaner housing or the engine intake. The housing is retained by the two M6 screws on one end and a series of slots and tabs on the other end.
5. Maintenance 8-2019 FIGURE 40. AIR CLEANER ELEMENT IN THE HOUSING TOP 6. Pull up on the fastener end of the housing top and slide it back to release it from the tabs. 7. Remove the dirty cleaner element. 8. Dispose of the dirty cleaner element in accordance with local environmental agency requirements. AIR CLEANER ELEMENT INSTALLATION 1. Clean the gasket surface on the air cleaner housing base. 2. Place the new air cleaner element in the air cleaner housing top. 3.
8-2019 5. Maintenance 6. Re-install the access panel and tighten the screws. Torque 3.5 - 5.0 ft-lb (5.0 6.6 Nm). 7. Reconnect the battery and restore the original generator set settings. 5.5 Batteries Batteries are an essential part of any standby generator set system. A significant amount of generator set failures are due to battery issues. It is therefore vital that batteries are stored, commissioned, and maintained as detailed here.
5. Maintenance 8-2019 CAUTION Toxic Hazard Electrolyte is a dilute sulphuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. Wear full eye protection and protective clothing. If electrolyte contacts the skins, wash it off immediately with water. If electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention. Wash spilled electrolyte with an acid neutralizing agent. NOTICE Keep batteries upright to prevent spillage.
8-2019 5. Maintenance Vented Batteries WARNING Toxic Hazard The electrolyte in vented batteries is a dilute sulfuric acid that is harmful to the skin and eyes. It is also electrically conductive and corrosive. Always: 1. Wear full eye protection and protective clothing; 2. If the electrolyte contacts the skin, wash it off immediately with water; 3. If the electrolyte contacts the eyes, flush them thoroughly and immediately with water and seek medical attention; and 4.
5. Maintenance 8-2019 Always: • Keep the battery case and terminals clean and dry and the terminals tight. • Remove battery cables with an insulated wrench or battery terminal puller. • Make sure which terminal is positive (+) and which is negative (–) before making battery connections, always removing the negative (–) cable first and reconnecting it last to reduce arcing.
8-2019 5. Maintenance 4. Inspect the wear pattern of the brush block and measure each brush to make sure it falls within the tolerances of normal operation. Replace as necessary. 5. Tighten the brush block and make sure it has full contact with the slip rings. 6. Replace the brush block access cover and start the generator set. 5.7 Cleaning the Generator Set Housing The housing of the generator set housing can be damaged by pressure washing or solvents and other cleaning agents.
5. Maintenance 8-2019 NOTICE If the test fails, call your authorized Cummins service provider to fix the problem. Copyright © 2019 Cummins Inc.
6 Troubleshooting 6.1 Avoiding Generator Set Shutdowns By regularly performing the following periodic maintenance and guidelines, you will greatly reduce the chances of a generator set shutdown: • Maintain an appropriate oil level. • Keep battery connections clean and tight. • Do not overload the generator set. • Keep the air inlet and outlet openings clear. Refer to the Maintenance section for more information. 6.
6. Troubleshooting 8-2019 2. Recharge or replace recommendations. battery. Refer to the battery manufacturer's 3. Have the battery charger serviced by an authorized Cummins dealer. No AC Power - Generator Set Running Logic: Circuit breakers have tripped due to overload or short. Possible Causes: 1. Circuit breakers 2. Customer loads Diagnosis and Repair: 1. Circuit breakers a. Reset or turn on the generator set circuit breaker. b. Reset or turn on the circuit breaker in the distribution panel. c.
8-2019 6. Troubleshooting Code 2 - Low Oil Pressure Fault Possible Causes: • Faulty oil pressure relief valve • Faulty oil pump • Faulty switch • Oil level too low/high Diagnosis and Repair: 1. Check the oil level. 2. Add or drain oil as necessary. 3. If the previous steps do not resolve the problem, contact your Cummins service representative for assistance.
6. Troubleshooting 8-2019 • Wire connections Corrective Action: 1. Have the unit serviced by an authorized Cummins dealer. Code 13 - Undervoltage Possible Causes: • Generator set loads • Wire connections • Windings Corrective Action: 1. Have the unit serviced by an authorized Cummins dealer.
8-2019 6. Troubleshooting • Ignition • Wire connections Diagnosis and Repair: 1. Reduce the number of connected loads especially loads that require higher starting current, such as air conditioners. 2. Have the unit serviced by an authorized Cummins dealer. Code 19 - Governor Actuator Shutdown Possible Causes: • Governor actuator • Wire connections Corrective Action: 1. Have the unit serviced by an authorized Cummins dealer.
6. Troubleshooting 8-2019 WARNING Some generator set service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform generator set service. Code 29 - High Battery Voltage Possible Causes: • Control • Faulty charger • Incorrect battery configuration • Wire damage Corrective Action: 1. Have the battery charger serviced by an authorized Cummins dealer.
8-2019 6. Troubleshooting Code 35 - Control Card Failure Possible Cause: Faulty program Corrective Action: 1. Have the unit serviced by an authorized Cummins dealer. Code 36 - Generator Set Stopped without Fault Condition Possible Causes: • Air fuel mixture • Alternator windings • Carburetor • Demand regulator • Exhaust system • Fuel supply • Ignition • Wire connections Diagnosis and Repair: 1. Check the fuel source. 2. Open any closed fuel valves. 3. Secure spark plug leads to spark plugs. 4.
6. Troubleshooting 8-2019 Code 45 - Speed Sense Fault Possible Causes: • Alternator windings • Loads • Wire connections Corrective Action: 1. Have the unit serviced by an authorized Cummins dealer. Code 46 - Generator Set Overload Possible Causes: • Loads • Windings • Wire connections Corrective Actions: 1. Reduce the number of connected loads especially loads that require higher starting current such as air conditioners. 2. Check and service air filter as necessary. 3.
8-2019 6. Troubleshooting 2. The web page or app has encountered an error. 3. The mobile device or computer has experienced an error. 4. The Connect Cloud is unavailable. Diagnosis and Repair: 1. Connection problems exist between the mobile device or computer and the Connect Cloud. a. Refer to the Mobile Device or Computer Connection Problem section. 2. The web page or app has encountered an error. a. Close the web browser and access the Connect Cloud from a new browser window. b.
6. Troubleshooting 8-2019 ii. Check the generator set control board for illuminated green and orange lights (also known as the “heartbeat”) near the Ethernet port. If the board is properly communicating with the network, the lights should flicker on and off irregularly. c. Battery voltage is low. • Refer to the Starting Battery Runs Down or Low Battery Warning Is Active section. d. The customer’s modem or router has no Internet connectivity. i.
8-2019 6. Troubleshooting 4. The control board software is not current. • Ensure the control board software matches the latest version available. See the Control Software Updates section for information on how to perform control software updates. 5. There is a generator set control board problem. • If there is still a problem after you have completed all other troubleshooting, it is possible the control board has a problem and must be replaced.
6. Troubleshooting 8-2019 No Email Notifications Are Being Received Possible Causes: 1. The incorrect email address was entered. 2. Emails are being filtered by a spam filter. 3. Connection problems exist between the generator set and the Connect Cloud. 4. The Connect Cloud is unavailable. 5. There is a generator set control board failure. Diagnosis and Repair 1. The incorrect email address was entered. • Verify the email address by using Preferences, Manage Users on the Connect Cloud. 2.
8-2019 6. Troubleshooting Diagnosis and Repair: 1. Data has not been refreshed. • Refresh the web page or the mobile app by using the refresh function in the menu or by swiping down. 2. Connection problems exist between the mobile device or computer and the Internet. • Refer to the Mobile Device or Computer Connection Problem section. 3. The user is not logged in. • Make sure that you are logged in using the correct username and password. 4. The Internet connection is slow.
6. Troubleshooting 8-2019 3. Connection problems exist between the mobile device or computer and the Connect Cloud. • Refer to the Mobile Device or Computer Connection Problem section. 4. The generator set is receiving a remote start command, but another failure has occurred preventing the generator from starting. a. Check the local or remote display, the mobile app, or the website for faults on the generator set. b. Attempt to start the generator set from the local display. 5.
8-2019 6. Troubleshooting 2. The Connect Cloud is unavailable. • Verify availability by accessing the Connect Cloud from another device and/or another browser. Generator Set Starts or Stops Unexpectedly Possible Causes: 1. An accidental web page or mobile app start/stop command was received. Diagnosis and Repair: 1. An accidental web page or mobile app start/stop command was received. a. The mobile app has the option to enable a PIN for any start/stop commands.
6. Troubleshooting 8-2019 This page is intentionally blank. Copyright © 2019 Cummins Inc.
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