Service Manual Generator Set for Home Standby C13N6H (Spec B) C17N6H (Spec B) C20N6H (Spec B) C20N6HC (Spec B) English Original Instructions 10-2019 A062J683 (Issue 1)
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 10-2019 5.3 Engine Oil ............................................................................................................................. 5.4 Engine Valve Clearance ....................................................................................................... 5.5 Normal Duty Air Cleaner Element Replacement .................................................................. 5.6 Exhaust System Maintenance ..................................................................
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 10-2019 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.
10-2019 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 10-2019 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.
10-2019 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. Moving Parts Can Cause Severe Personal Injury or Death • Keep hands, clothing, and jewelry away from moving parts.
1. IMPORTANT SAFETY INSTRUCTIONS FIGURE 1. 10-2019 HATCHED AREAS Make sure this consideration is captured in your risk assessment. 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.
10-2019 1. IMPORTANT SAFETY INSTRUCTIONS NOTICE It is the policy of Cummins Inc. to perform all electrical work in a deenergized 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 deenergizing the equipment would create a greater risk or make the task impossible and all other alternatives have been exhausted.
1. IMPORTANT SAFETY INSTRUCTIONS 10-2019 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.
10-2019 1. IMPORTANT SAFETY INSTRUCTIONS • 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.
1. IMPORTANT SAFETY INSTRUCTIONS 1.7 10-2019 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.
10-2019 1. IMPORTANT SAFETY INSTRUCTIONS 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. A062J683 (Issue 1) 11 Copyright © 2019 Cummins Inc.
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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.
2. Introduction 2.2 10-2019 Test Equipment To perform the test procedures in this manual, the following test equipment must be available: • True RMS (Root Mean Square) meter for accurate measurement of small AC and DC voltages • Grounding wrist strap to prevent circuit board damage due to electrostatic discharge (ESD) • Wheatstone bridge or digital ohmmeter • Load bank • Megger or insulation resistance meter 2.3 Schedule of Abbreviations This list is not exhaustive.
10-2019 2. Introduction Abbr. Description Abbr.
2. Introduction 10-2019 Abbr. 2.4 Description Abbr.
10-2019 2. Introduction • RA Series Automatic Transfer Switch Owner Manual (A046S594) (models RA112N3, RA212N3, RA112S3, RA212S3, RA412N3, and RA412S3) - if applicable • Parts Manual (A053X179) • Standard Repair Times - HO Family (A053X186) • Service Tool Manual (A043D529) • Warranty Failure Code Manual (F1115C) • Engineering Application Manual T-030: Liquid Cooled Generator Sets (A040S369) 2.5 Model Specifications TABLE 1.
2. Introduction 10-2019 TABLE 3. FUEL CONSUMPTION SPECIFICATIONS (AT FULL LOAD) C13N6H Type C17N6H C20N6H, C20N6HC Fuel Pressure kPa in water column scfh BTU/hr scfh BTU/hr scfh BTU/hr Natural Gas 228 217,200 258 246,000 268 256,000 0.9–3.0 3.5–12 Propane 83 197,700 102 242,400 112 266,000 1.5–3.0 6–12 Note: Maximum pressure for either fuel under any condition: 3.2 kPa (13 inch water column) TABLE 4.
10-2019 2. Introduction TABLE 5. GENERATOR SET SIZE Dimension TABLE 6. Value Length 865 mm (34.1 in) Width 915 mm (36 in) Height 694 mm (27.3 in) 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...
2. Introduction 10-2019 TABLE 9. CONTROL SPECIFICATIONS Control Integrated Microprocessor-Based Engine, Alternator, Transfer Switch Controller 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.
10-2019 2. Introduction NOTICE Damage caused by failure to follow the manufacturer's recommendations will not be covered by the warranty. Please contact your authorized service provider. Warranty Limitations For details of the warranty limitations for your generator set, refer to the warranty statement applicable to the generator set. How to Obtain Service When a product requires service, contact the nearest authorized Cummins service provider. To locate the service provider, refer to www.cummins.
2. Introduction 10-2019 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.
10-2019 Facility MEXICO 2. Introduction Address Eje 122 No. 200 Zona Industrial San Luis Potosi, S.L.P. 78395 Mexico A062J683 (Issue 1) Phone Numbers Phone +52 444 870 6700 Fax +52 444 824 0082 23 Copyright © 2019 Cummins Inc.
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3 Startup 3.1 "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. Startup 10-2019 FIGURE 2. CLOCK SETUP SCREEN 4. Select the Next key to go to the Daylight Savings screen. Copyright © 2019 Cummins Inc.
10-2019 3. Startup 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. A062J683 (Issue 1) 27 Copyright © 2019 Cummins Inc.
3. Startup 10-2019 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.
10-2019 3. Startup 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). A062J683 (Issue 1) 29 Copyright © 2019 Cummins Inc.
3. Startup 10-2019 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.
10-2019 3.3 3. Startup "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. Startup 10-2019 • 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.
10-2019 3. Startup FIGURE 7. A062J683 (Issue 1) EXERCISE SETUP SCREEN 33 Copyright © 2019 Cummins Inc.
3. Startup 3.4 10-2019 "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.
10-2019 3. Startup FIGURE 8. A062J683 (Issue 1) BRIGHTNESS AND CONTRAST SCREEN 35 Copyright © 2019 Cummins Inc.
3. Startup 3.5 10-2019 "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. Copyright © 2019 Cummins Inc.
10-2019 3. Startup FIGURE 9. A062J683 (Issue 1) ABOUT SCREEN 37 Copyright © 2019 Cummins Inc.
3. Startup 3.6 10-2019 "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 10. Copyright © 2019 Cummins Inc.
10-2019 3.7 3. Startup "Fault Log" Screen To retrieve information from the Fault Log: 1. From the Main screen, select Menu. 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.
3. Startup 10-2019 FIGURE 11. 3.8 FAULT LOG SCREEN "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. Copyright © 2019 Cummins Inc.
10-2019 3. Startup FIGURE 12. 3.9 SYSTEM STATUS SCREEN "Mode" Screen WARNING To prevent unexpected starts from remote devices, disable Remote mode and disconnect the connector on the back of the local display wired to any remote mounted displays.
3. Startup 10-2019 NOTICE The Remote function can only be activated (that is, enabled) from the local display. When Standby is on or set to Enabled, the “Standby On” LED on the front of the display will illuminate indicating the control will start the generator set in response to a utility power outage. Standby can be turned on at the local display. It can also be enabled with a remote display, web page, or a cell phone app if Remote has already been enabled at the local display.
10-2019 3. Startup FIGURE 13. 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. Startup 10-2019 3.10 Automatic Load Management NOTICE The capability to automatically add or remove specific electrical loads from the generator set requires that load management devices be wired to the generator set load management outputs. 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.
10-2019 3. Startup 4. Although the generator set is shipped from the factory with the proper level of engine oil, check the oil level before it is started. 5. Start and test the system. 6. Operate the generator set following all the instructions and precautions in the operator manual. NOTICE Before leaving the site, if the generator set is ready to be placed in service, enable the Remote and Standby modes from the local display.
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4 Operation 4.1 Introduction This section describes the operation of the generator set. The text should be read in conjunction with the Control System section of this manual. All indicators, control switches/buttons, and graphical display are located on the face of the local and remote displays. CAUTION To avoid injury, be sure to read the instructions in the Operating the Generator Set Cover Safely section before lifting the generator set cover. 4.
4. Operation 10-2019 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.
10-2019 4. Operation FIGURE 16. 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 17. 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.
4. Operation 10-2019 FIGURE 18. UTILITY RE-TRANS 5. When utility power is stable for 5 minutes, the transfer switch connects the building load back to utility power. FIGURE 19. UTILITY RETURNED 6. The generator set runs an additional 5 minutes to cool down and then shuts off. FIGURE 20. ENGINE COOLDOWN 7. Normal operation resumes. See Figure 15. Exercise Sequences 1. Standard Exercise sequence: NOTICE Standby Mode must be enabled for standard exercise to execute. Copyright © 2019 Cummins Inc.
10-2019 4. Operation 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 21. EXERCISE CYCLE STARTED b. After the generator set reaches rated speed and voltage, the exercise timer is started.
4. Operation 10-2019 FIGURE 22. EXERCISING c. When the defined exercise time has completed, the generator set stops and normal operation resumes. FIGURE 23. 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.
10-2019 4. Operation 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 24. 4.
4. Operation 10-2019 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 25. 4.5 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.
10-2019 4. Operation 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 26. TYPICAL FAULT SCREEN Press the BACK button to reset the fault and return to the home screen. The red FAULT light will shut off.
4. Operation 10-2019 FIGURE 29. AUTO STOP – UTILITY RETURNED FIGURE 30. FIGURE 31. 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. Copyright © 2019 Cummins Inc.
10-2019 4. Operation NOTICE Refer to the Periodic Maintenance Schedule section for more information. FIGURE 32. SCHEDULED MAINTENANCE REMINDER EXAMPLE FIGURE 33. LOW BATTERY VOLTAGE WARNING FIGURE 34. 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. A062J683 (Issue 1) 57 Copyright © 2019 Cummins Inc.
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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 10-2019 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.
10-2019 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 10-2019 FIGURE 35. 5.2 HINGE LOCATION Periodic Maintenance WARNING Electrical Generating Equipment Accidental or remote starting of the generator set can cause severe personal injury or death. Before working on the generator set, make sure that the generator set is in Off mode, disable the battery charger, and remove the negative (–) battery cable from the battery to prevent starting. The table(s) that follow show the recommended service intervals for a generator set on standby service.
10-2019 5. Maintenance At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance.
5. Maintenance 10-2019 WARNING Automatic startup of the generator set can cause severe personal injury or death. Make sure the generator set is shut down and disabled: 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. Turn off and disconnect the battery charger from the AC source before disconnecting the battery cables. 3.
10-2019 5. Maintenance A "New Event" screen appears and the yellow service LED turns on whenever one of the following scheduled maintenance time periods occurs: 1. First 25 hours of generator set running 2. First 100 hours of generator set running 3. After the first 100 hours, every 200 hours of generator set running Press the BACK button to turn off the light and return to the home screen. See the "Fault" and "New Event" Screens section for more information. 5.
5. Maintenance 10-2019 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 36. Copyright © 2019 Cummins Inc.
10-2019 5. Maintenance No. 1 Description No. Engine Oil Level Dipstick FIGURE 37. 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.
5. Maintenance 10-2019 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.
10-2019 5. Maintenance 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.
5. Maintenance 10-2019 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.
10-2019 5. Maintenance 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.
5. Maintenance No. 10-2019 Description No. Description 1 Control Access Panel (Horizontal Panel Above Control Board) 6 Intake Air Panel 2 Exhaust Panel 7 Alternator-End Panel 3 Engine-End Panel 8 Alternator-End Inner Panel 4 Engine-End Inner Panel 9 Exhaust-Side Inner Panel 5 Intake-Side Inner Panel 10 Exhaust Access Panel (Horizontal Panel Above Muffler) FIGURE 38. REMOVAL OF PANELS 5. Remove the oil filter access panel. 6.
10-2019 5. Maintenance No. Description No. Description 1 Rocker Arm 4 Valve Spring Plate 2 The dimension of the clearance between the rocker arm and the valve collet is the valve clearance. 5 Valve Spring 3 Valve Collet 6 Valve FIGURE 39. VALVE ASSEMBLY If it is out of specification, adjust the intake valve clearance to the lower specification limit. TABLE 12. VALVE CLEARANCE SPECIFICATIONS Valve Clearance Ambient (mm) Hot (mm) 0.10–0.15 0.2 0.15–0.20 0.
5. Maintenance 10-2019 13. Using the socket and extensions attached to the flywheel bolt, rotate the engine clockwise until the exhaust valve closes, and the intake valve begins to open. 14. Check the valve clearance and if it is out of specification, adjust the exhaust valve clearance to the lower specification limit (see step 11). 15. Repeat steps 9 through 14 to adjust the intake and exhaust valves for the remaining cylinder. 16. Assemble the valve cover using a new valve cover gasket.
10-2019 5.5 5. Maintenance Normal Duty Air Cleaner Element Replacement NOTICE Cummins Inc. does not recommend cleaning paper-type air cleaner elements. AIR CLEANER ELEMENT REMOVAL 1. Make sure the generator set is shut down and disabled: a. 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. b. Turn off and disconnect the battery charger from the AC source before disconnecting the battery cables. c.
5. Maintenance No. 1 10-2019 Description No. Air Cleaner Housing FIGURE 41. 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.
10-2019 5. Maintenance FIGURE 42. 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.
5. Maintenance 10-2019 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. 5.6 Exhaust System Maintenance WARNING Hot Exhaust Components Exhaust components become very hot when the generator set is in use and remain hot for a period of time after the generator set has been shut down. These components can cause severe personal injury or death from contact.
10-2019 5.7 5. Maintenance DC Electrical System 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.
5. Maintenance 10-2019 Storage Batteries must be stored in a cool, dry, well-ventilated place, in the upright position, and with the vent caps securely in place. Batteries must never be stacked on top of each other and must be protected from the floor by a wooden pallet or suitably thick cardboard sheet. General Precautions for Maintenance-Free Batteries Handling and proper use of batteries is not hazardous if the correct precautions are observed and personnel are trained in their use.
10-2019 5. Maintenance Fire Hazard WARNING Combustible Gases Lead acid batteries present a risk of fire because they generate hydrogen gas. Do not smoke near the batteries. Do not cause flame or spark in the battery area. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface. WARNING Before disconnecting a battery, always remove power from the AC powered battery charger.
5. Maintenance 10-2019 Battery Maintenance WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Arcing at battery terminals or in light switches or other equipment, and flames or sparks can ignite battery gas causing severe personal injury. Always follow these procedures to avoid injury and/or damage: • Ventilate the battery area before working on or near the battery. • Wear safety glasses. • Do not smoke.
10-2019 5. Maintenance NOTICE Never allow a battery to become completely flat (fully discharged), or to stand in a discharged condition, or damage will result. Battery Replacement WARNING Combustible Liquid Burning the battery may cause an explosion. Damage to the casing will release electrolytes which is harmful to the skin and eyes. When disposing of a battery, do not mutilate or burn it. Comply with all local health and safety regulations/codes during handling or disposal.
5. Maintenance 10-2019 NOTICE Do not use anything other than a Scotch Brite pad as this will cause damage to the slip rings and alternator. 4. Replace the brush block access cover and start the generator set. 5.12 Exercising the Generator Set NOTICE Audible engine RPM variation may be heard while there is no load applied. This is normal and does not affect generator set performance. Exercising the generator set re-lubricates the engine and removes oxides from electrical contacts.
10-2019 5. Maintenance 2. Place the generator set in Standby mode. 3. Switch the main utility disconnect from the ON to the OFF position. 4. Make sure the following occurs: a. The generator set starts. b. After the generator set starts and stabilizes, the load is transferred from the utility to the generator set. 5. Switch the main utility disconnect from the OFF to the ON position. 6. Make sure the following occurs: a. After approximately 5 minutes, the load is transferred back to the utility. b.
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6 Service 6.1 Control System The generator set control system continuously monitors the engine and the alternator. If an abnormal condition is sensed, either the yellow Service lamp or the red Fault lamp will illuminate and a message will be displayed on the local and remote displays. In the event of a generator set shutdown fault (red Fault LED), the control will stop the generator set immediately.
6. Service 10-2019 Control Components No. Description No. Description 1 B+ Battery Cable 7 Control Board 2 Battery Charger 8 Fuel Shutoff Valve 3 Local Display 9 Circuit Breaker 4 Oil and Battery Heater Temperature Switch 10 Battery 5 Current Transformers 11 Alternator Temperature Switch 6 Governor Actuator FIGURE 44. Copyright © 2019 Cummins Inc.
10-2019 6. Service Generator Set Control Type Description General The generator set control is an integrated microcontroller-based engine, alternator and transfer switch control. It provides all the control, monitoring and diagnostic functions required to operate this generator set. Transfer Switch Control When a transfer switch without a built-in controller is used, all transfer and retransfer signals come from the generator set control.
6. Service 10-2019 WARNING Automated Machinery When the generator set is in Remote mode, it may start unexpectedly. Accidental or remote starting of the generator set can cause severe personal injury or death. Because any display configured as “Local” can enable the generator set’s Remote mode, make sure that only the display located at the generator set is configured as “Local”. To access the HMI Type screen: 1. From the Main screen, select Menu. 2.
10-2019 6. Service FIGURE 45. DISPLAY SETUP MENU NAVIGATION "Generator Config" Screen The display's Generator Config screen has two generator set parameters (Config and Fuel Type) that must be configured if the control board is replaced or reconfigured; failure to do so will result in Fault Code 37. To configure the generator set: 1. From the Main screen, select Menu. 2. Press and hold the Next key on the Menu screen for at least 5 seconds to view the Config Menu.
6. Service 10-2019 3. Use the arrow keys to highlight "Config" and click the Enter key. The Generator Config screen appears. 4. The default setting for the Config field is 1. Use the Next key to navigate to the Config field. Use the arrow keys to select the appropriate config option. Config Option Model 23 C20N6H, C20N6HC 24 C17N6H 25 C13N6H 5. Use the Next key to navigate to the Fuel Type field. Use the arrow keys to select the fuel type: NG (natural gas; default) or LP (liquid propane).
10-2019 6. Service FIGURE 46. GENERATOR CONFIG SCREEN "Adjustments" Screen The display's Adjustments screen within the Generator Config screen has two generator set parameters that are used to configure the readings on the generator set HMI screen only. 1. From the Main screen, select Menu. A062J683 (Issue 1) 93 Copyright © 2019 Cummins Inc.
6. Service 10-2019 2. Press and hold the Next key on the Menu screen for at least 5 seconds to view the Config Menu. 3. Use the arrow keys to highlight "Adjustments" and click the Enter key. The Adjustments screen appears. 4. Use the Next and Previous keys to select the parameter to be changed. 5. Use the arrow keys to adjust the parameter to the appropriate value. NOTICE The parameter values on the Adjustments screen are for HMI purposes only.
10-2019 6. Service Control Board Replacement 1. Make sure the generator set is shut down and disabled: a. 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. 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 first and secure it from contacting the battery terminals to prevent accidental starting.
6. Service 10-2019 TABLE 13. PART NUMBER EXAMPLES Model C13N6H A061C591 C17N6H A061C596 C20N6H A061C601 C20N6HC A061C602 FIGURE 48. Copyright © 2019 Cummins Inc.
10-2019 6. Service FIGURE 49. MENU SCREEN 10. Set the generator output and fuel type in the Generator Config screen, as described in the Generator Config screen section. A062J683 (Issue 1) 97 Copyright © 2019 Cummins Inc.
6. Service 10-2019 11. Optional: Re-install the Ethernet cord into the control. 12. Install the control access panel and close the hood. NOTICE If the Ethernet cable was plugged in before the serial number and model number were entered, briefly remove and re-install the Ethernet cable from the control or the router, or power-cycle the control. 6.2 Fuel System Fuel System Components No. Description No.
10-2019 6. Service See the Model Specifications section for the maximum permissible fuel supply pressure for propane vapor and natural gas. Converting the Fuel System Type The generator set leaves the factory set up for natural gas. For operation on liquid propane vapor, the generator set must be converted by configuring the generator set control for propane and manually changing the fuel valve position from natural gas to propane. 1.
6. Service 10-2019 FIGURE 51. GENERATOR CONFIG SCREEN 2. Adjust the manual fuel selector to the LP setting: a. Lift the top cover. b. Remove 2 screws on top of the exhaust panel. Copyright © 2019 Cummins Inc.
10-2019 6. Service No. 1 Description No. Exhaust Panel Screws FIGURE 52. 2 Description Exhaust Panel (Rear) EXHAUST PANEL REMOVAL c. Remove the exhaust panel. d. Remove 2 screws securing the fuel selector access cover and remove access cover. No. Description No. Description 1 Fuel Selector Access Cover Screws 4 Access Opening 2 Fuel Selection Handle Access 5 Fuel Selector Valve 3 View from Face of Regulator (panels not shown) FIGURE 53.
6. Service 10-2019 e. Reach through the fuel selection handle access opening and turn the handle counterclockwise until it reaches detent (90° from starting position). NOTICE The handle should be horizontal for LP, vertical for NG. f. Reinstall the fuel selector access cover. Torque screws to 5–6.6 Nm (44–58 in-lb). g. Reinstall the exhaust panel. Torque screws to 5–6.6 Nm (44–58 in-lb). h. Close the generator set cover.
10-2019 6. Service 2. Open the generator set breaker. 3. Before disconnecting the generator set battery, note the exercise schedule settings. 4. Disconnect the generator set battery, negative post first, then positive post. 5. Open the hood and make sure the hood latch drops into place. 6. Remove the control access panel. See the figure in the Control Components section. 7. Disconnect the two actuator leads from the main harness. 8. Remove and retain the clip that holds the socket on the ball. 9.
6. Service 10-2019 No. Description No. Description 1 Ball Socket 3 Pivot Joint 2 Upper Jam Nut 4 Lower Jam Nut FIGURE 54. GOVERNOR LINKAGE ASSEMBLY 2. Attach the governor actuator and mounting bolts to the actuator bracket. 3. Install the governor linkage assembly in the generator set. NOTICE If replacing the actuator with a new part, install the electrical connectors similar to those on the actuator being replaced on the new part.
10-2019 6. Service FIGURE 55. ACTUATOR IN FULLY RETRACTED POSITION 6. Verify that the mixer arm can be moved (with the linkage installed) to the fully open position. 7. Tighten the jam nuts against the base of the ball socket and the base of the pivot joint. 8. Connect the electrical leads from the wiring harness to the governor actuator. 9. Install the control access panel. 10. Connect the generator set battery and reset the display settings, including the exercise schedule. 11.
6. Service 10-2019 c. Disconnect the negative (–) cable from the battery first and secure it from contacting the battery terminals to prevent accidental starting. Then disconnect the positive cable. 2. Remove the necessary enclosure panels and service access panels (and oil cooler if needed) to access to the cylinder head. 3. Remove the engine shield below the valve cover. 4. Remove the four valve cover mounting bolts, valve cover and valve cover gasket.
10-2019 6. Service NOTICE Make sure to clean off all of the gasket material from the engine block mating surface. Caution should be taken to not scratch or alter the mating surface as this may cause leaks when reassembled. 7. Install the locating sleeves and the new head gasket. 8. Install the new cylinder head assembly, tightening the bolts in the pattern shown below to 50 Nm (36.9 ft-lb). FIGURE 57. CYLINDER HEAD ASSEMBLY BOLT TORQUE SEQUENCE 9.
6. Service 10-2019 FIGURE 58. VALVE ADJUSTMENT BOLT TORQUE SEQUENCE 13. Re-install the intake and exhaust manifolds, and related parts. 14. Re-install the panels that were removed in step 2. 15. Reconnect the battery by first connecting the positive terminal first, then the negative terminal. 16. Restore power to the AC accessories and restore the generator set settings. 17. If possible, test run the generator set with load. 6.
10-2019 6.5 6. Service Alternator Alternator Components This is a single-bearing, two-pole, revolving field alternator with brushes and slip rings. Output voltage is regulated by the generator set control. Here are the major components: Component Description Stator The stator consists of steel laminations with two sets of windings in the lamination slots. The main windings (L1-L2, Neutral) power the connected loads and the quadrature windings (Q1-Q2) supply power for the alternator field.
6. Service No. 10-2019 Description No. Description 1 Stator 7 O-Ring 2 Rotor 8 Rotor Mounting Washer and Nut 3 Commutator Ring Assembly 9 Brush Block Mounting Screws 4 Bearing 10 Threaded Rod (Rotor Mounting Stud) 5 End Bell (Bracket) 11 Access Cover 6 Brush Block Assembly 12 Threaded Rod (Mounting Stud) FIGURE 59. Copyright © 2019 Cummins Inc.
10-2019 6. Service Alternator Heater DANGER Live Electrical Conductors Live electrical conductors can cause serious injury or death by electric shock and burns. To prevent injury and before removing covers over electrical conductors, isolate the generator set from all energy sources, remove stored energy and use lock out/tag out safety procedures. Power to the alternator heater is supplied from a separate AC source.
6. Service 10-2019 NOTICE Make sure that the brushes are aligned correctly with the slip rings; otherwise, the brushes may break when the generator set is started. b. If the slip rings have grooves, pits, or other damage, use a Scotch Brite pad or commutator stone to remove light wear or corrosion. 6. Re-install the brush block cover. Testing the Alternator 1. Rotor Winding Continuity: a.
10-2019 6. Service Tests Measurement Values L1 to L2 Value should be equal to sum of L1 to N and L2 to N measurements above ± 1% Ohms Q1 to Q2 • 13 kW = 2.56 +/– 10% Ohms • 17/20 kW = 1.45 +/– 10% Ohms L1 to Q1 Infinity L1 to Gnd Infinity L2 to Gnd Infinity Sense L1(W) - Sense L2(V) • 13 kW = 0.24 +/– 10% Ohms • 17/20 kW = 0.
6. Service 10-2019 For these products, generator set output power is equal to amperage multiplied by line to line voltage; that is, power (Watts) = amperage x voltage (L-L). The C17N6H generator set model is rated at 70.8 Amps, at 240 V Line to Line, which is equal to a power of 17,000 Watts (70.8 A x 240 V). If the generator set is operating at its rated elevation and temperature, and the voltage is reduced from 240 to 230 volts, the amperage will increase from 70.8 to 73.
10-2019 6. Service Factor Values Operating Elevation - Rated Elevation = Total ft Above Rated Derate for Elevation 2750 ft – 1000 ft = 1750 ft Total ft Above Rated/1000 ft = Elevation Ratio 1750/1000 = 1.75 Elevation Ratio x Derate Schedule = % Reduction of output from Elevation (Elevation Reduction) 1.75 x 3.5% = 6.1% 93 °F – 77 °F = 16 °F 16/10 = 1.6 1.6 x 3% = 4.8% 6.1% + 4.8% = 10.9% 10.9/100 = 0.
6. Service 10-2019 NOTICE The Automatic Voltage Regulator (AVR) contains electronic components which would be damaged by high voltage applied during insulation resistance tests. The AVR must be disconnected before doing any insulation resistance test. Temperature sensors must be grounded to earth before doing any insulation resistance test. Damp or dirty windings have a lower electrical resistance and could be damaged by insulation resistance tests at high voltage.
10-2019 6. Service WARNING Live Electrical Conductors Live electrical conductors at the winding terminals after an insulation resistance test can cause serious injury or death by electric shock or burns. To prevent injury, discharge the windings by shorting to earth through an earthing rod for at least 5 minutes. Requirements TABLE 16. WINDING TEST REQUIREMENTS Requirement Description Personal Protective Equipment (PPE) Wear mandatory site PPE.
6. Service No. 10-2019 Description No. Description 1 Control Access Panel (Horizontal Panel Above Control Board) 6 Intake Air Panel 2 Exhaust Panel 7 Alternator-End Panel 3 Engine-End Panel 8 Alternator-End Inner Panel 4 Engine-End Inner Panel 9 Exhaust-Side Inner Panel 5 Intake-Side Inner Panel 10 Exhaust Access Panel (Horizontal Panel Above Muffler) FIGURE 60. REMOVAL OF PANELS 9. Remove the alternator-end panel, hood, and cross braces.
10-2019 6. Service FIGURE 61. BLOCKING THE ALTERNATOR FOR REMOVAL c. Loosen the rotor retaining nut. d. Double nut the rotor through-stud by adding an M12 x 1.75 nut to the loosened rotor nut. e. Unthread the rotor through-stud, and remove it along with the washer and nuts. f. Expose the fan hub and end of the rotor. FIGURE 62. FAN HUB AND END OF ROTOR g. Insert a 14 mm x 2.0 bolt into the end of the rotor. FIGURE 63. A062J683 (Issue 1) 14 MM X 2.0 BOLT 119 Copyright © 2019 Cummins Inc.
6. Service 10-2019 h. Attach a bar-type gear/wheel puller with 2 M6 x 1.0 bolts into the fan hub. i. Push the head of the 14 mm x 2.0 bolt and pull the fan hub off the rotor. FIGURE 64. PULLING FAN HUB OFF ROTOR 11. Remove the exhaust muffler. 12. Remove the alternator-end inner panel. 13. Disconnect the battery charger wiring harness from the intake-side inner panel. 14. Disconnect the alternator leads from the circuit breaker. NOTICE Note which CT each stator lead passes through.
10-2019 6. Service 20. Remove the rotor as follows: a. Remove the stator and through-studs. b. Remove the nut and flat washer on the rotor through-stud. c. Use the 2 nuts locked together at the end of the rotor through-stud to loosen and remove the through-stud from the crankshaft. d. Thread in a rotor removal tool. e. Using the groove in the end of the rotor removal rod, turn the rod with a screwdriver until it bottoms in the crankshaft. f. Thread in and tighten an M14 x 2.
6. Service 10-2019 k. Remove the exhaust manifold. l. Remove the isolator mount nuts and isolators. m. Remove the engine. ALTERNATOR AND ENGINE INSTALLATION 1. If a new engine is being installed, install the dipstick shipped with the engine. Apply a bead of Loctite 518 (or equivalent high temperature thread sealant) on the underside of the dipstick mounting flange around the perimeter of the tube. Tighten mounting bolts to 9.8–11.9 Nm (7.2–8.8 ft-lb).
10-2019 6. Service iii. Align the stator through-bolts with the engine mounting hole, and thread them into the holes. Torque the stator through-bolts by hand. iv. Insert the rotor through-bolt and thread it into the engine crankshaft by hand until the bolt bottoms out. v. While viewing from the non-drive end, torque the stator through-bolt nuts as follows, with a progression of 2 o’clock, 8 o’clock, 10 o’clock, and 4 o’clock each time: Initial 27–33 Nm (19.9–24.
6. Service 10-2019 f. Install the other mixer gasket to the face of the air box. Position the intake manifold gaskets into place (2 per side). g. Carefully position the intake manifold so the mixer studs go into the holes on the air box and the manifold goes over the 4 studs on the engine. h. Install the nuts to secure the intake manifold to the engine. Torque the nuts to 11–14 Nm (8–10.3 ft-lb). i. Inside the air box, install the breather baffle over the studs.
10-2019 6. Service 17. Install the remaining alternator ground strap bolt with the following parts on the skid in the following order: a. Star washer b. Flat washer c. Alternator ground strap d. Flat washer e. Bolt Torque the bolt to 5–6.2 Nm (44–55 ft-lb). 18. Route the alternator leads through the correct CT and onto the circuit breaker. Torque the fasteners to 4–5 Nm (35–44 in-lb). 19. Attach the oil cooler to the intake-side inner enclosure panel. Torque the bolts to 5.6–6.6 Nm (50–58 in-lb). 20.
6. Service 10-2019 25. Connect the wiring harness lead to the terminal on the brush block holder. Make sure to place the correct lead on the correct connector on the brush block holder. 26. Install the brush block cover. Torque the fastener to 3.2–4.0 Nm (28–35 in-lb). 27. Reconnect AC accessory power wiring to terminal blocks TB-LINE and TBNEUTRAL, as well as round. Do not turn the power on for the AC accessory power connections. 28. Install the top access panels. 29. Connect the battery charger (BC-P).
10-2019 6. Service 47. Close the main utility breaker. The transfer switch will transfer power back to the utility and enter engine cooldown mode. The engine will stop automatically in approximately 10 minutes. Torque Specifications TABLE 17. Area TORQUE SPECIFICATIONS Component Metric Imperial Alternator Alternator Fan/Rotor Retention Nut 113–139 Nm 83.3–102.5 ft-lb Alternator Alternator Ground Strap/B - to End Bell Bolt 12.3–15 Nm 9–11 ft-lb Alternator Alternator Heater 18–22 Nm (or 1.
6. Service 10-2019 Area Component Metric Imperial Enclosure Muffler Mounting Bolts 9.8–11.9 Nm 7.2–8.8 ft-lb Enclosure Oil Cooler Bolts 5.6–6.6 Nm 50–58 in-lb Enclosure Service Access Panel Bolts 5.6–6.6 Nm 50–58 in-lb Enclosure Solenoid Mounting Bracket Bolts 9.8–11.9 Nm 7.2–8.8 ft-lb Engine Airbox Cover Bolts 3.2–4.0 Nm 28–35 in-lb Engine Airbox Mounting Brackets Bolts 3.2–4.0 Nm 28–35 in-lb Engine Airbox to Mixer/Throttle Body Nuts 3.2–4.
10-2019 6.6 6. Service Placing the Generator Set Back in Service If the control board is replaced, it will be necessary to configure the replacement control board. See the "Generator Config" Screen section for more information. When all service and maintenance is completed on the generator set, the generator set control should be set to standby if it is safe to do so, or to an alternate state if requested by the customer. 6.
6. Service 10-2019 • One set of two leads from the customer wiring that is installed in the lugs at the bottom of the breaker (L1 and L2) 3. Check continuity as follows: • When the breaker is on (that is, the contacts inside the breaker are closed), the continuity check should show very low resistance between the pair of L1 lugs and the pair of L2 lugs. • When the breaker is off (that is, the contacts inside the breaker are open), the continuity check between L1 and L2 pairs should show open.
7 Troubleshooting 7.1 Troubleshooting Procedures This section is a guide to help you evaluate problems with the generator set. You can save time if you read through the entire manual ahead of time and understand the system.
7. Troubleshooting 10-2019 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.
10-2019 7. Troubleshooting TABLE 18. GATRR TROUBLESHOOTING APPROACH Icon Description G - Gather: Gather customer information, review service history, complete visual inspection, and perform system operation check. Attempt to safely recreate the issue. A - Analyze: Narrow down the possibilities by system and identify likely problem components. T - Test: Perform tests in order of likelihood based on troubleshooting tees and symptoms present.
7. Troubleshooting 10-2019 • Alternator and engine removal and installation: ◦ Tools: ▪ Piece of standard 2 x 4 lumber cut to 4 in ▪ Socket or similar tool less than 18.6 mm (0.73 in) in diameter ▪ Wheel/gear puller ▪ Rotor removal tool ◦ Parts: ▪ Nut (M12 x 1.75) ▪ Bolt (M14 x 2.0) ▪ Intake manifold gaskets (4) ▪ Throttle body to airbox gasket ▪ Throttle body to intake manifold gasket ▪ Exhaust manifold gaskets (2) ▪ Engine oil (see the Model Specifications section) 7.
10-2019 7. Troubleshooting WARNING Electric Shock Hazard Batteries present the risk of high short circuit current. Remove watches, rings, or other metal objects. Use tools with insulated handles. NOTICE Servicing of batteries must be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. When the battery voltage falls below approximately 13.2 VDC, the charging current will be constant at 4 Amps.
7. Troubleshooting 10-2019 TABLE 19. Problem TROUBLESHOOTING Possible Causes No AC power Action Check the supply breaker. Replace the fuse. Fuse specification: 5 x 20 mm, time lag (time delay) glass body cartridge fuse rating 5 A, 250 VAC. See the figure below for the fuse location. No Charger Output Blown fuse and Low Battery Charger failure (see the charge curve) Check the LEDs and wiring; replace the charger if required.
10-2019 7.7 7. Troubleshooting Engine Flywheel Battery Charger Troubleshooting 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. WARNING Electric Shock Hazard Batteries present the risk of high short circuit current. Remove watches, rings, or other metal objects. Use tools with insulated handles.
7. Troubleshooting 10-2019 FIGURE 69. FUSE LOCATION 1. Remove utility power from the utility-power battery charger. 2. Attach a DC voltmeter to the battery and record the battery voltage while the generator set is not running. 3. Open the generator set's AC output breaker to prevent the ATS from transferring to generator set power. 4. Manually start the generator set. 5. Record the battery voltage with the generator set running. 6.
10-2019 7. Troubleshooting b. If there is no output and battery voltage is less than 13.8 ±0.5 VDC, stop the generator set and disconnect the 4-pin plug going to the flywheel regulator. i. Connect an AC voltmeter across the pins of the plug connected to the yellow wires supplying AC power to the regulator from the flywheel alternator. ii. Verify 50 ±5 VAC across the yellow wires. • If 50 ±5 VAC is not available: ◦ Verify that the blue wire of the flywheel alternator is at ground.
7. Troubleshooting 10-2019 TABLE 21. COMPRESSION TEST SPECIFICATIONS Cylinder psi Cylinder 1 >150 Cylinder 2 >150 For access to valve covers, refer to Section 5.4 on page 71. Tools Required: • General mechanical tools (metric and English socket set, etc.) • Compression test kit • LocTite Threadlocker Blue 242 or equal • Torque wrench • Valve cover gaskets (2). PN: A050X455 • Feeler gauge set Compression Test Instructions: 1. Shut off the fuel supply to the generator set. 2.
10-2019 7. Troubleshooting 7.10 Connecting with the InPower Service Tool NOTICE The InPower tool cannot be connected to the C13N6H, C17N6H, and C20N6H model HMIs. To connect to the SAAC control using the InPower service tool: 1. Make sure the control is not in sleep mode. Pressing STOP will wake up the control and disable Standby and Remote modes. 2. Remove the J1 plug from back of the HMI (display). 3. Locate the J5 plug (see Figure 71). FIGURE 71. J5 LOCATION 4.
7. Troubleshooting 10-2019 7.11 Troubleshooting by Symptom Generator Set Starts when Utility Power Is Available - No Fault Code Logic: To start - the generator set control receives ground at start input on the generator set control board with Standby enabled, or from a remote display or monitoring system (web page or phone app) with Remote enabled.
10-2019 7. Troubleshooting 3. Verify that both the battery voltage and condition are acceptable. Minimum voltage for display operation is 8V. 4. Measure battery voltage at the battery while attempting to start from the local or remote display. a. Recharge or replace the battery if the voltage drops below 8 VDC. b. Test and service the generator set battery charger. 5. Check electrolyte level and hydrometer reading in maintenance-type batteries. a. Replace electrolyte if necessary. b.
7. Troubleshooting 10-2019 • Faulty control board • Faulty starter Diagnosis and Repair: 1. Attempt to replicate the fault. 2. Measure the battery voltage at the connector P1. battery, at the generator set, and at • Reconnect, clean, repair, and replace connections as necessary. 3. Measure the battery voltage from the local or remote display. at the generator set while starting • Recharge or replace the battery if the voltage drops below 8 VDC.
10-2019 7. Troubleshooting Possible Causes: 1. Marginal battery connections 2. Faulty battery 3. Charging system 4. Excessive cranking 5. Control electrical draw Diagnosis and Repair: 1. Check the last fault recorded. • If this fault has not been repaired, troubleshoot that fault. 2. Measure battery voltage at the battery and at the positive battery post on the starter. If the voltage levels are not the same, go to the next step. 3.
7. Troubleshooting 10-2019 5. Verify engine battery charger is functioning correctly. Measure battery voltage and check for voltage increase while the generator set is running. No AC Power but Generator Set Is Running Logic: There is no AC power to the connected loads but the generator set is running Possible Causes: • The generator set circuit breaker has tripped due to an overload or short or was turned off • The ATS failed to transfer to the generator set source Diagnosis and Repair: 1.
10-2019 7. Troubleshooting Possible Causes: • Low/high oil level • Faulty oil pressure switch • Faulty oil pressure relief valve in engine • Harness is faulty (unintentional ground in circuit) • Faulty oil pump Diagnosis and Repair: 1. Check the last fault recorded. • If this fault has not been repaired, troubleshoot that fault. 2. Measure the oil level. • Add or drain oil if necessary. 3. Disconnect the plug from the oil pressure switch and measure continuity from P1-6 and GND.
7. Troubleshooting 10-2019 • Oil viscosity • Iced or corroded brushes or slip rings (open/shorted excitation circuit) • Open/shorted quad sense or quad winding • Failed AVR/field flash circuit • Slow cranking speed Diagnosis and Repair: 1. Check the last fault recorded. • If this fault has not been repaired, troubleshoot that fault. 2. Verify that the fuel valve external to the generator set is open. 3. Disconnect the generator set control P1 connector. 4.
10-2019 7. Troubleshooting 12. Propane models only: a. When ambient temperatures are less than 4.4 °C (40 °F), the vapor withdrawal propane tanks should be at least half full to provide proper vaporization rate. b. Propane that has more than 2.5% butane will not vaporize in ambient temperatures at less than 0 °C (32 °F) so make sure to use HD-5 grade propane. c. Verify tank level and fuel line conditions. 13. Verify that the fuel solenoid valve is open. 14.
7. Troubleshooting 10-2019 20. Measure field, quadrature, and main winding resistance. • Clean the slip rings, replace the brushes, repair the harness, and replace the rotor and stator assembly if necessary. 21. Check the battery heater to make sure if it is functioning properly (if applicable). a. Verify that the heater thermostat is functioning properly. b. If a battery heater is recommended for ambient temperature and not installed, install a battery heater. 22.
10-2019 7. Troubleshooting 5. Remove connector P1 from the control and re–install it, and then start the generator set. 6. Verify that the P1 pin socket is fully inserted and inspect the pin socket condition for corrosion and acceptable condition of contact wipers. To check contact wipers, use one of the devices below: • A mating pin connector • A pin gauge the same size as the mating control connector pin (0.
7. Troubleshooting 10-2019 5. Remove connector P1 from the control and re–install it, and then start the generator set. 6. Verify that the P1 pin socket is fully inserted and inspect the pin socket condition for corrosion and acceptable condition of contact wipers. To check contact wipers, use one of the devices below: • A mating pin connector • A pin gauge the same size as the mating control connector pin (0.
10-2019 7. Troubleshooting • Air fuel mixture • Exhaust system • Demand regulator • Throttle plate • Alternator windings • Wire connections Diagnosis & Repair: 1. Check the last fault recorded. • If this fault has not been repaired, troubleshoot that fault. 2. Measure the AC current while running the generator set with loads. • Identify faulty or short cycling loads. 3. Disconnect the generator set control P1 connector. 4.
7. Troubleshooting 10-2019 10. Check the generator set fuel lines for damage. • Replace the fuel line if necessary. 11. Check the governor actuator, actuator linkage, and throttle shaft for free smooth motion without slop. Verify that the actuator is opening the throttle while cranking. 12. Measure the field, quadrature, and main winding resistance. • Clean the slip rings, replace the brushes, repair the harness, and replace the rotor and stator assembly if necessary. 13. Check brush alignment: a.
10-2019 7. Troubleshooting 5. Disconnect the generator set control P1 connector. 6. Verify that the P1 and P2 pin sockets are fully inserted and inspect the pin socket condition for corrosion and acceptable condition of contact wipers. To check contact wipers, use one of the devices below: • A mating pin connector • A pin gauge the same size as the mating control connector pin (0.
7. Troubleshooting 10-2019 17. Measure field, quadrature, and main winding resistance. • Clean the slip rings, replace the brushes, repair the harness, and replace the rotor and stator assembly if necessary. 18. Check brush alignment: a. Inspect brush wear on the slip rings and verify brush misalignment is toward the windings. b. If the misalignment is toward the bearing, the cause is not a tolerance issue but is more likely the result of the end bell not being seated properly during assembly.
10-2019 7. Troubleshooting • Automatic Transfer Switch (ATS) Diagnosis & Repair: 1. Check the last fault recorded. • If this fault has not been repaired, troubleshoot that fault. 2. Measure and verify governor actuator resistance (2.8 Ohms ±5%). • Replace if necessary. 3. Measure and verify governor wiring to the control. • Replace or repair if necessary. 4. Disconnect the generator set control P1 connector. 5.
7. Troubleshooting 10-2019 • Fuel supply • Air fuel mixture • Exhaust system • Governor actuator • Ignition system • Elevated ambient temperature • Cooling air flow blockage Diagnosis & Repair: 1. Check the last fault recorded. • If this fault has not been repaired, troubleshoot that fault. 2. Open the generator set circuit breaker so no load is on the product and run the generator set. • If the same fault occurs, troubleshoot the actuator control or fuel system.
10-2019 7. Troubleshooting 10. Check for air filter cleanliness. • Replace the air filter if necessary. 11. Propane models only: • When ambient temperatures are less than 40 °F (34.4 °C), vapor withdrawal propane tanks should be at least half full to provide the proper vaporization rate. • Propane having more than 2.5% butane will not vaporize in ambient temperatures at less than 32 °F (0 °C); use HD-5 grade propane. • Verify tank level and fuel line conditions. 12.
7. Troubleshooting 10-2019 ii. Verify that the magnet that is in the flywheel is still magnetic, is not damaged, and/or has not been misplaced. Replace the flywheel if necessary. iii. If the magneto coil is still not functioning properly, replace it. d. Inspect the spark plugs for damage and proper gap: • Remove and inspect spark plugs. If they are damaged or dirty, replace them. • Measure the spark plug gap. Re-gap if necessary.
10-2019 7. Troubleshooting 8. Measure field, quadrature, and main winding resistance. • Clean the slip rings, replace the brushes, repair the harness, and replace the rotor and stator assembly if necessary. 9. Check brush alignment: a. Inspect brush wear on the slip rings and verify brush misalignment is toward the windings. b. If the misalignment is toward the bearing, the cause is not a tolerance issue but is more likely the result of the end bell not being seated properly during assembly.
7. Troubleshooting 10-2019 6. Inspect the condition of the P1 pin on the control board. If it is damaged or severely corroded, clean or repair if possible, or replace the control board. 7. When reconnecting the harness plug to the connector, ensure that the pair are fully seated next to each other. 8. Reconnect the P1 connector and test-run the generator set for fault occurrence.
10-2019 7. Troubleshooting 7. Inspect the condition of the P1 pin on the control board. If it is damaged or severely corroded, clean or repair if possible, or replace the control board. 8. When reconnecting the harness plug to the connector, ensure that the pair are fully seated next to each other. 9. Measure DC voltage at the starter during a start attempt. a. Repair wire connections as necessary. b. Replace the start solenoid and starter as necessary. 10. Check for air filter cleanliness.
7. Troubleshooting 10-2019 c. Check the magneto output: i. Using a spark tester, verify that the magneto coils are providing acceptable output. If the output is not acceptable, verify proper magneto gap (see Section 2.5 on page 17), and re-gap if necessary. ii. Verify that the magnet that is in the flywheel is still magnetic, is not damaged, and/or has not been misplaced. Replace the flywheel if necessary. iii. If the magneto coil is still not functioning properly, replace it. d.
10-2019 7. Troubleshooting Diagnosis & Solution: 1. Check the last fault recorded. • If this fault has not been repaired, troubleshoot that fault. 2. Replace the control. Code 36 - Generator Set Stopped Without Fault Condition Logic: RPM is less than 500 and sense voltage S1-S2 is at 0 VAC and no other fault condition occurred Possible Causes: • Fuel supply • Air fuel mixture • Exhaust system • Demand regulator • Throttle plate • Alternator windings • Ignition • Wire connections Diagnosis & Repair: 1.
7. Troubleshooting 10-2019 8. Check for air filter cleanliness. • Replace the air filter as necessary. 9. Check for a blocked or damaged exhaust system. • Repair or replace exhaust components as necessary. 10. Measure the generator set load capability with a shop load bank. 11. Propane models only: a. When ambient temperatures are less than 40 °F (34.4 °C), vapor withdrawal propane tanks should be at least half full to provide the proper vaporization rate. b. Propane having more than 2.
10-2019 7. Troubleshooting d. Inspect the spark plugs for damage and proper gap: • Remove and inspect spark plugs. If they are damaged or dirty, replace them. • Measure the spark plug gap. Re-gap if necessary. 18. Measure temperature of the air intake and temperature rise across the generator set. • Remove the blockage or prevent air recirculation as necessary. Code 37 - Invalid Set Configuration Logic: Generator set control configuration does not meet any valid configuration.
7. Troubleshooting 10-2019 Diagnosis & Repair: 1. Check the last fault recorded. • If this fault has not been repaired, troubleshoot that fault. 2. Inspect slip rings and clean them as required. 3. Disconnect the generator set control P1 connector. 4. Measure the quadrature winding resistance between pin sockets P1-2 and P13; compare that to the value in the table in the Alternator section. a. If open or shorted, measure quadrature winding resistance at pins of AC-J 1 and 2 and compare to table value.
10-2019 7. Troubleshooting 2. Measure the AC current and voltage while running the generator set with all connected loads. a. Identify faulty or short cycling loads. b. Reduce loads as necessary. (The Cummins load management kit can be used to automatically reduce connected loads.) Code 61 - E-Stop Active Logic: Occurs when E-Stop switch is grounded. Once activated, it cannot be cleared unless the switch is opened. Possible Causes: 1. Activated local E-Stop button 2.
7. Troubleshooting 10-2019 2. Verify the generator set air inlet and air outlet panels are not obstructed. Verify that there are no foreign objects within the enclosure that limit air flow. 3. Disconnect the generator set control P1 connector. 4. Verify that the P1 pin socket is fully inserted and inspect the pin socket condition for corrosion and acceptable condition of contact wipers.
10-2019 7. Troubleshooting Diagnosis and Repair: 1. The generator set is not connected to the Internet. a. Verify the Internet connection status on the generator set local or remote display. This information is displayed on the Cloud Info screen in the MENU – About. • If the control is failing to connect to the Internet after multiple tries, power-cycle the control. b. Check the generator set control board for the IP address and data transfer “heartbeat”. i.
7. Troubleshooting 10-2019 2. There are router and/or firewall problems. • Reset the firewall settings on the modem or router. The remote monitoring system requires open communication to 168.61.54.255 on port 8884 and 40.114.00.153 on port 8885. Refer to the modem or router owner’s manual for the proper procedure. • It is also possible the Internet service provider is blocking communication to these addresses or these ports outside of the customers network.
10-2019 7. Troubleshooting • The mobile device or computer cellular data signal strength is acceptable. b. If you are unable to resolve an Internet connection problem, contact the cellular data or Internet Service Provider. 3. The customer’s modem or router does not have Internet connectivity. a. Check the Internet connection indicator on the modem or router. • If the Internet connection indicator is not illuminated, reset the modem or router.
7. Troubleshooting 10-2019 6. The Connect Cloud is unavailable. • Verify availability by accessing the Connect Cloud from another device, and/or another browser. Generator Set Does Not Respond to Start and/or Stop Commands from the Web Page or Mobile App Possible Causes: 1. Remote Enable is not enabled at the local display. 2. Connection problems exist between the generator set and the Connect Cloud. 3. Connection problems exist between the mobile device or computer and the Connect Cloud. 4.
10-2019 7. Troubleshooting Mobile App Push Notifications Do Not Appear Possible Causes: 1. Push notifications are not enabled in the Connect Cloud app. 2. Mobile device application permissions do not allow push notifications. Diagnosis and Repair: 1. Push notifications are not enabled in the Connect Cloud app. • Enable push notifications in the Connect Cloud app settings. 2. Mobile device application permissions do not allow push notifications.
7. Troubleshooting 10-2019 Webpage or Mobile App Does Not Respond Possible Causes: 1. Connection problems exist between the mobile device or computer and the Connect Cloud. 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.
Appendix A. Wiring Diagrams Table of Contents Figure 72. Wiring Diagram (Sheet 1 of 6) ................................................................................................. 179 Figure 73. Wiring Diagram (Sheet 2 of 6) ................................................................................................. 180 Figure 74. Wiring Diagram (Sheet 3 of 6) ................................................................................................. 181 Figure 75.
Appendix A. Wiring Diagrams A.0 10-2019 Wiring Diagrams The drawings included in this section are representative. For current complete information, refer to the drawing package that was shipped with the unit. Copyright © 2019 Cummins Inc.
10-2019 Appendix A. FIGURE 72. A062J683 (Issue 1) Wiring Diagrams WIRING DIAGRAM (SHEET 1 OF 6) 179 Copyright © 2019 Cummins Inc.
Appendix A. Wiring Diagrams 10-2019 FIGURE 73. Copyright © 2019 Cummins Inc.
10-2019 Appendix A. FIGURE 74. A062J683 (Issue 1) Wiring Diagrams WIRING DIAGRAM (SHEET 3 OF 6) 181 Copyright © 2019 Cummins Inc.
Appendix A. Wiring Diagrams 10-2019 FIGURE 75. Copyright © 2019 Cummins Inc.
10-2019 Appendix A. FIGURE 76. A062J683 (Issue 1) Wiring Diagrams WIRING DIAGRAM (SHEET 5 OF 6) 183 Copyright © 2019 Cummins Inc.
Appendix A. Wiring Diagrams 10-2019 FIGURE 77. Copyright © 2019 Cummins Inc.
10-2019 Appendix A. FIGURE 78. A062J683 (Issue 1) Wiring Diagrams HARNESS, GENERATOR SET ELECTRICAL (SHEET 1 OF 3) 185 Copyright © 2019 Cummins Inc.
Appendix A. Wiring Diagrams 10-2019 FIGURE 79. Copyright © 2019 Cummins Inc.
10-2019 Appendix A. FIGURE 80. A062J683 (Issue 1) Wiring Diagrams HARNESS, GENERATOR SET ELECTRICAL (SHEET 3 OF 3) 187 Copyright © 2019 Cummins Inc.
Appendix A. Wiring Diagrams 10-2019 This page is intentionally blank. Copyright © 2019 Cummins Inc.
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