Operator Manual Generator Set with QSJ5.9G Engine and PowerCommand® 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 3-2018 5.5 Air Intake System.................................................................................................................. 5.6 Batteries................................................................................................................................ 5.7 Spark Plugs .......................................................................................................................... 77 79 83 6. TROUBLESHOOTING ......................................
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 3-2018 General Safety Precautions WARNING Hot Pressurized Liquid Contact with hot liquid can cause severe burns. Do not open the pressure cap while the engine is running. Let the engine cool down before removing the cap. Turn the cap slowly and do not open it fully until the pressure has been relieved. WARNING Moving Parts Moving parts can cause severe personal injury. Use extreme caution around moving parts.
3-2018 1. IMPORTANT SAFETY INSTRUCTIONS 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. WARNING Toxic Hazard Ethylene glycol, used as an engine coolant, is toxic to humans and animals. Wear appropriate PPE.
1. IMPORTANT SAFETY INSTRUCTIONS 3-2018 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). NOTICE Keep multi-type ABC fire extinguishers close by. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels.
3-2018 1. IMPORTANT SAFETY INSTRUCTIONS • Before starting work on the generator set, disconnect the battery charger from its AC source, then disconnect the starting batteries using an insulated wrench, negative (–) cable first. This will prevent accidental starting. • Make sure that fasteners on the generator set are secure. Tighten supports and clamps; keep guards in position over fans, drive belts, etc.
1. IMPORTANT SAFETY INSTRUCTIONS 3-2018 Do Not Operate in Flammable and Explosive Environments Flammable vapor can cause an engine to over speed and become difficult to stop, resulting in possible fire, explosion, severe personal injury, and death. Do not operate a generator set where a flammable vapor environment can be created, unless the generator set is equipped with an automatic safety device to block the air intake and stop the engine.
3-2018 1. IMPORTANT SAFETY INSTRUCTIONS 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. • 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. • Wear safety glasses. • Do not smoke. • Do not charge frozen batteries.
1. IMPORTANT SAFETY INSTRUCTIONS 3-2018 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.
3-2018 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 3-2018 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 © 2018 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 3-2018 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.
3-2018 2. Introduction ABBR. CMM CT D-AVR DESCRIPTION ABBR.
2. Introduction 3-2018 ABBR. 2.4 DESCRIPTION ABBR. DESCRIPTION LBNG Lean-burn Natural Gas UL Underwriters Laboratories LCD Liquid Crystal Display UPS Uninterruptible Power Supply VPS Valve Proving System 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 to familiarize themselves with the warnings and operating procedures.
3-2018 2. Introduction • RA Series Transfer Switch Owner Manual (A046S594) - if applicable • PowerCommand® 1302 Controller Owner's Manual (900-0661) • Service Tool Manual (A043D529) • Standard Repair Times - HL Family (A053K365) • T-030: Liquid Cooled Generator Set Application Manual (A040S369) - for application information 2.5 Model Specifications NOTICE Damage caused by failure to follow the manufacturer's recommendation will not be covered by the warranty. Please contact your authorized distributor.
2. Introduction 3-2018 TABLE 3. Type Liquid Propane Full Load Natural Gas Full Load FUEL SPECIFICATIONS 60 HZ, 1800 RPM Unit C45 N6 C50 N6 C60 N6 C70 N6 C80 N6 C100 N6 scfh 289.6 321.6 370.2 384.2 420.8 518.7 BTU/hr 651,600 723,600 832,950 864,450 946,800 1,167,075 scfh 711.2 806.3 933.8 988.4 1,083.5 1,317.7 BTU/hr 721,868 818,395 947,807 Fuel Pressure 1,003,226 1,099,753 1,337,466 6-13 inches of water column (1.5 - 3.2 kPa) under any condition TABLE 4.
3-2018 2. Introduction Type Specification • Must adhere to Cummins® Engineering Standard (CES) 20085 • Use of improper oils can result in engine damage. Use only the required oils: ◦ 5W-40 (all ambient temperatures) ◦ 15W-40 (above 4 °C [40 °F] ambient temperature) (use of GEO 15W-40 oil in ambient temperatures below 4 °C (40 °F] could result in engine turbocharger damage) Oil Standards • A sulfated ash limit of 0.
2. Introduction 3-2018 TABLE 7. Configuration GENERATOR SET WET WEIGHT (POUNDS) (60 HZ, 1800 RPM) C45 N6 C50 N6 C60 N6 C70 N6 C80 N6 C100 N6 Open 2180 2180 2431 2449 2587 2719 Weather 2359 2359 2610 2628 2766 2898 Sound Level 1 2455 2455 2706 2724 2862 2994 Sound Level 2 2485 2485 2736 2754 2892 3024 NOTICE Weights are approximate and can be affected by selected options. Refer to outline drawings for specific weight information. TABLE 8.
3-2018 2. Introduction TABLE 9. GENERATOR SET DERATING GUIDELINES Engine Power Available Up To... Model Phase C45 N6 Elevation Ambient Temperature Both 675 m (2200 ft) 40 °C (104 °F) C50 N6 Both 150 m (490 ft) 25 °C (77 °F) C60 N6 Both 1000 m (3280 ft) 1 2575 m (8450 ft) C70 N6 C80 N6 C100 N6 Elevation 4% 40 °C (104 °F) per 300 m (985 ft) 3 3048 m (10000 ft) 1 1825 m (5985 ft) 3 2500 m (8200 ft) 1 700 m (1560 ft) 25 °C (77 °F) 3 1000 m (3280 ft) 40 °C (104 °F) TABLE 10.
2. Introduction 3-2018 Maintenance WARNING Electrical Generating Equipment Incorrect service or parts replacement can result in severe personal injury, death, and/or equipment damage. Make sure service personnel are qualified to perform electrical and mechanical service. For expert generator set service at regular intervals, contact your Cummins Inc. service provider. See power.cummins.com/sales-service-locator for service locations that service this application.
3-2018 2. Introduction • Do not store anything inside of the generator set. • Keep areas clear in front of the cool air in and hot air out (free of obstructions, debris, plants, etc.). NOTICE All maintenance procedures must be performed or supervised by authorized and trained service personnel only. No. Description No. Description 1 Cool Air In 2 Hot Air Out (Sound Level Enclosure) FIGURE 1. 2.
2. Introduction 3-2018 NOTICE Unauthorized modifications or replacement of fuel, exhaust, air intake or speed control system components that affect engine emissions are prohibited by law in the State of California. Model, Spec, and Serial Numbers: Be ready to provide the model, spec, and serial numbers on the generator set nameplate when contacting Cummins Inc. for information, parts, and service.
3-2018 2.9 2. Introduction 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.
2. Introduction Facility MEXICO 3-2018 Address Eje 122 No. 200 Zona Industrial San Luis Potosi, S.L.P. 78395 Mexico Copyright © 2018 Cummins Inc.
3 Control System 3.1 Control System Description The control system is used to start and stop the generator set, and provides full generator set monitoring capability and protection in a stand-alone situation (nonparalleling) from the display screen. It monitors the engine for temperature, as well as oil pressure and speed. It also provides voltage and current metering. In the event of a fault, the unit indicates the fault type and, on critical faults, automatically shuts down the generator set.
3. Control System 3-2018 FIGURE 2. STANDARD OPERATOR PANEL (HMI211) Standard Key Functions (HMI211) The user interface includes two fixed action buttons and four soft key buttons. The action of the soft key buttons changes to meet the requirements of each screen. TABLE 12. Key/Symbol KEY FUNCTIONS Action Switches to Off mode (fixed action button). Switches to Auto mode. Switches to Manual Run mode. Navigates to the previous menu level (fixed action button).
3-2018 3. Control System Key/Symbol Action - Decreases value of the highlighted editable field. + Increases value of highlighted editable field. Standard LED Indicators (HMI211) The operator panel has six LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below. TABLE 13. LED Color LED INDICATORS Action Not in Auto Red Indicates the generator set is in Manual or Off Mode. Shutdown Red Indicates a Shutdown Fault has occurred.
3. Control System 3-2018 FIGURE 3. IN-HOME OPERATOR PANEL Key Functions (In-Home Operator Panel) The user interface includes two fixed action buttons and four soft key buttons. The action of the soft key buttons changes to meet the requirements of each screen. TABLE 14. Key/Symbol Stop KEY FUNCTIONS Action Switches to Off mode. This key works from any screen (fixed action button). (Up Arrow) Navigates to the previous screen/menu in a list. (Down Arrow) Navigates to the next screen/menu in a list.
3-2018 3. Control System LED Indicators (In-Home Operator Panel) The operator panel has five LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below. TABLE 15. LED Color Shutdown Red LED INDICATORS Action Indicates a Shutdown Fault has occurred. Warning Yellow Indicates a Warning Fault has occurred. Auto Start Green Indicates that the generator set has received a Remote Start Command.
3. Control System 3-2018 Symbol Text Battery Out of Range High or Pre-High Low or Pre-Low Annunciator Over Speed Crank Fail Emergency Stop 3.3 Exercise Settings NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without an RA series transfer switch. To access the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2.
3-2018 3. Control System FIGURE 4. A051X877 (Issue 7) CLOCK/EXERCISER MENU NAVIGATION 31 Copyright © 2018 Cummins Inc.
3. Control System 3-2018 Updating Exercise Frequency (3-Phase ATS) NOTICE Not applicable without an RA series transfer switch. To update the exercise frequency and dates on the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen. 4.
3-2018 3. Control System FIGURE 5. EXERCISE FREQUENCY NAVIGATION Updating Exercise Duration (3-Phase ATS) NOTICE Not applicable without an RA series transfer switch. To update the exercise duration on the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3.
3. Control System 3-2018 • Press Save to save any changes. After saving, the Save button changes to the Adjust button. FIGURE 6. EXERCISE DURATION NAVIGATION Time Setup (3-Phase ATS) NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without an RA series transfer switch. To set up the generator set clock for the current date and time: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2.
3-2018 3. Control System FIGURE 7. TIME SETUP SCREEN Updating Daylight Saving Adjust Screens Update Values on the Daylight Saving Adjust Screen 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Navigate to the Genset Service Menu. 3. Select Clock Exerciser to access the Time Setup screen. 4. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen. 5. Select Adjust.
3. Control System FIGURE 8. 3-2018 "DAYLIGHT SAVING ADJUST SAVING TIME" SCREEN NAVIGATION Access and Update the Daylight Saving Adjust Start Screen 1. Press the down arrow key on the Daylight Saving Adjust screen. 2. Press Adjust. When updating these settings, the functions of the keys are as follows: TABLE 18.
3-2018 3. Control System FIGURE 9. DAYLIGHT SAVING ADJUST START SCREEN Update the Daylight Saving Adjust End Screen 1. Press the down key on the Daylight Saving Adjust Start screen. 2. Press Adjust. When updating these settings, the functions of the keys are as follows: TABLE 19.
3. Control System 3-2018 FIGURE 10. 3.4 DAYLIGHT SAVING ADJUST END SCREEN Brightness and Contrast The Screen Adjust screen allows the contrast, brightness, and units to be set. To access the Screen Adjust screen: 1. From any Information screen, hold down the up and down arrows simultaneously for two seconds to gain access to the Service Menu screen. 2. Select Screen Adjust. To adjust the contrast, brightness, or units from the Screen Adjust screen: 1.
3-2018 3. Control System NOTICE The following screens represent the standard operator panel (HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels. FIGURE 11. A051X877 (Issue 7) BRIGHTNESS AND CONTRAST SCREEN NAVIGATION 39 Copyright © 2018 Cummins Inc.
3. Control System 3-2018 NOTICE Adjusting the brightness on the operator panel adjusts the brightness of both the LCD backlight and the LEDs on the display. The contrast should never be 0 or 100% on any of the screens. The default value for Brightness is 50%. 3.5 History and About Menu To access the History/About screen: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Select History/About. 3.
3-2018 3. Control System FIGURE 12. A051X877 (Issue 7) HISTORY/ABOUT MENU 41 Copyright © 2018 Cummins Inc.
3. Control System 3.6 3-2018 Fault Log To check the fault log: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Select Fault History. NOTICE The active faults are displayed first. If there are no active faults, this screen is skipped. Following the Active Faults screen are the Fault History screens. These screens display the faults in chronological order from newest to oldest.
3-2018 3. Control System FIGURE 13. A051X877 (Issue 7) FAULT LOG SCREEN 43 Copyright © 2018 Cummins Inc.
3. Control System 3.7 3-2018 Selecting Operating Modes Selecting Manual Run Mode WARNING Electrical Generating Equipment When changing modes, the generator set can start or stop without warning (for example, Auto Mode may have been selected with no mains (utility) power available). Make sure there is no danger to personnel or equipment, if the generator set starts or stops when changing modes. 1. Before proceeding to change the mode, make sure that it is safe to do so. 2.
3-2018 3. Control System No. Description No. Description 1 Menu Displayed Only When the Mode Change Access Code Feature Is Enabled 2 Alternating Arrows Displayed FIGURE 14. A051X877 (Issue 7) 3 Manual Run Mode Selected SELECTING MANUAL RUN MODE 45 Copyright © 2018 Cummins Inc.
3. Control System 3-2018 Selecting Auto Mode WARNING Electrical Generating Equipment When changing modes, the generator set can start or stop without warning (for example, Auto Mode may have been selected with no mains (utility) power available). Make sure there is no danger to personnel or equipment, if the generator set starts or stops when changing modes. To switch to Auto mode (see Figure 15 on page 47), 1. Ensure that it is safe to do so before proceeding to change the mode. 2.
3-2018 3. Control System No. Description No. Description 1 This Menu Is Displayed Only if the Mode Change Access Code Feature Is Enabled 2 Alternating Arrows Are Displayed FIGURE 15. A051X877 (Issue 7) 3 Auto Mode Selected SELECTING AUTO MODE 47 Copyright © 2018 Cummins Inc.
3. Control System 3-2018 Selecting Off Mode WARNING Electrical Generating Equipment When changing modes, the generator set can start or stop without warning (for example, Auto Mode may have been selected with no mains (utility) power available). Make sure there is no danger to personnel or equipment, if the generator set starts or stops when changing modes. To switch to Off mode (see the figure below), 1. Make sure that it is safe to do so before proceeding to stop the set. 2.
3-2018 3. Control System No. Description 1 No. Description Off Button 2 FIGURE 16. 3.8 This Mode Is Displayed Only if the Mode Change Access Code Feature Is Enabled SELECTING OFF MODE Operating Modes The generator set's PowerCommand® control has Manual Run, Off, and Auto operating modes that are available from the operator panel. A051X877 (Issue 7) 49 Copyright © 2018 Cummins Inc.
3. Control System 3-2018 Off Mode When in Off mode, the control does not allow the generator set to start. If the generator set is already running and the control is set to Off, it initiates a normal shutdown sequence. Manual Run Mode When in Manual Run mode, the generator set starts and continues to run until the control is put into the Off mode. While in Manual Run mode, the remote start signal is ignored.
4 Operation - PowerCommand 1.1 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 Operator Panel. 4.2 General Operating Conditions The area surrounding the generator set is critical for safety and its performance. Follow the guidelines below. • Do not stack anything on top of the generator set.
4. Operation - PowerCommand 1.1 3-2018 NOTICE Diesel engines only: Cummins Inc. recommends the installation of an air intake shutoff device or a similar safety device to minimize the risk of overspeeding where an engine will be operated in a combustible environment. NOTICE Long periods of idling (more than ten minutes) can damage an engine. Do not idle the engine for excessively long periods. Sequence of Operation NOTICE The following sequences are based on an approximate time duration.
3-2018 4. Operation - PowerCommand 1.1 NOTICE The control box area is equipped with an ambient temperature sensor for controlling the idle feature. Do not install any heaters in the control box area as this can influence the sensor and lead to engine damage. 5. After the generator set ramps up to rated speed, the generator set provides voltage to the transfer switch, but the transfer switch does not switch (allowing the voltage to go to the building) until after a delay. FIGURE 18.
4. Operation - PowerCommand 1.1 3-2018 FIGURE 21. TIME REMAINING UNTIL RE-TRANSFER 9. When the utility power is stable for 5 minutes, the transfer switch switches back to utility power. FIGURE 22. BUILDING LOAD TRANSFER IN PROCESS FIGURE 23. UTILITY POWERING BUILDING LOAD 10. The generator set runs for a 5-minute cooldown and shuts off. FIGURE 24. TIME REMAINING UNTIL STOP 11. Normal operation resumes.
3-2018 4. Operation - PowerCommand 1.1 2. If the ambient temperature is below 20 °F (6.7 °C), the generator set will idle at 800 rpm for up to 2 minutes to allow sufficient turbo lubrication. • Idle time is linear from 2 minutes at -40 °F (4 °C), or below to off at 20 °F (6.7 °C) or above. FIGURE 25. COLD START IDLE ACTIVE 3. The Exerciser Scheduler On screen displays every 3 seconds and toggles between the existing Information screen that is displayed for 1 second. FIGURE 26.
4. Operation - PowerCommand 1.1 3-2018 NOTICE Open the generator set main line circuit breaker to prevent the transfer switch from transferring building load to the generator set. The generator set display will still show the RA series ATS transfer; however, the switch will not transfer if the generator set breaker is open. 1. In normal operation, the utility power is running to the transfer switch and then to the building load, and the generator set is off. 2.
3-2018 4. Operation - PowerCommand 1.1 FIGURE 28. COLD START IDLE ACTIVE 5. The generator set provides voltage to the transfer switch. (However, the transfer switch does not transfer in manual mode.) Remote Starting the Generator Set Sequence If the generator set is remote started with the in-home operator panel accessory, if equipped (the generator set is in Auto Mode), the sequence is as follows: 1.
4. Operation - PowerCommand 1.1 FIGURE 29. 3-2018 HMI211 SET IN AUTO MODE 3. Manually start the generator set via the in-home operator panel. Copyright © 2018 Cummins Inc.
3-2018 4. Operation - PowerCommand 1.1 FIGURE 30. MANUAL START SCREEN, IN-HOME OPERATOR PANEL 4. The generator set starts and provides voltage to the transfer switch, but the transfer switch does not switch (allowing the voltage to go to the building) until after a delay. FIGURE 31. TIME REMAINING UNTIL TRANSFER SCREEN 5. Five seconds after starting, the generator set provides a signal to the transfer switch to transfer the building load to the generator set.
4. Operation - PowerCommand 1.1 FIGURE 32. 3-2018 BUILDING LOAD TRANSFER IN PROCESS 6. If the ambient temperature is below 20 °F (6.7 °C) , the generator set will idle at 800 rpm for up to 2 minutes to allow sufficient turbo lubrication. • Idle time is linear from 2 minutes at -40 F (40 °C), or below to off at 20 °F (6.7 °C) or above. FIGURE 33. COLD START IDLE ACTIVE 7. The transfer switch switches the generator set power to the building load. The building is now running on generator power.
3-2018 4. Operation - PowerCommand 1.1 FIGURE 36. UTILITY POWERING BUILDING LOAD 9. The generator set runs for a 5-minute cooldown and shuts off. FIGURE 37. TIME REMAINING UNTIL STOP 10. Normal operation resumes. A051X877 (Issue 7) 61 Copyright © 2018 Cummins Inc.
4. Operation - PowerCommand 1.1 3-2018 This page is intentionally blank. Copyright © 2018 Cummins Inc.
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 3-2018 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.
3-2018 5. Maintenance Locking the Generator Set Out of Service NOTICE 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 (–) cable first. Before any work is carried out for maintenance, etc., the generator set must be immobilized.
5. Maintenance 5.2 3-2018 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.
3-2018 5. Maintenance Periodic Maintenance Schedule NOTICE Perform maintenance tasks as specified using daily or hourly periods, whichever is sooner. TABLE 20. Maintenance Items PERIODIC MAINTENANCE SCHEDULE After Every After Every 12 Months or 24 Hours 50 Hours After 250 of Run of Run Hours2 1 Time Time Check air cleaner restriction indicator (where fitted): If the indicator shows red, replace air cleaner element and reset the indicator.
5. Maintenance Maintenance Items 3-2018 After Every After Every 12 Months or 24 Hours 50 Hours After 250 of Run of Run Hours2 1 Time Time Check radiator airflow: Visually inspect the radiator through the guarding for blockage, debris or signs of wear or damage. To clean or replace, contact your authorized distributor. ■ Check fuel lines and hoses: Visually check for leaks, worn or damaged hoses. To replace, contact your authorized distributor.
3-2018 Maintenance Items 5. Maintenance After Every After Every 12 Months or 24 Hours 50 Hours After 250 of Run of Run Hours2 1 Time Time Check operation of Emergency Stop Button (where fitted): With the generator set running, press the Emergency Stop button. Check all systems before resetting the fault. ■ Replace air cleaner. ■3 Check coolant lines and radiator hoses for leaks, wear and cracks: Visually check the hoses. Replace worn or damaged components. ■ Clean radiator core.
5. Maintenance Maintenance Items 3-2018 After Every After Every 12 Months or 24 Hours 50 Hours After 250 of Run of Run Hours2 1 Time Time Check battery for general condition. Remove any corrosion on terminals with wire brush. ■ Check electrical connections (battery, starter motor, alternator connections). Check for tight connections, general condition and remove any corrosion. ■ ■4 Replace engine oil and filters. Refer to the Engine Oil section for the procedure.
3-2018 5. Maintenance Maintenance Items After Every After Every 12 Months or 24 Hours 50 Hours After 250 of Run of Run Hours2 1 Time Time Replace cooling system coolant. Check coolant sensor for damage and debris. 2 Years or After 500 Hours2 ■ 1 This interval is based on generator run time: daily in an outage or after every 24 hours of run time. 2 To be performed by a qualified Service Technician. 3 Cleaning schedule may be reduced depending on operating conditions/environment.
5. Maintenance 3-2018 NOTICE Use of improper oils can result in engine damage. Use only the recommended oils. NOTICE Use of GEO 15W-40 oil in ambient temperatures below 40 °F (4 °C) could result in engine turbocharger damage. Checking Engine Oil Level 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 (–) cable first.
3-2018 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 engine with the oil level below the low mark or above the high mark. No. Description No. Description 1 Fill Cap 3 Oil Filter 2 Dipstick 4 Oil Drain Hose FIGURE 38. ENGINE OIL COMPONENTS 1. Make sure the generator set is shut down and disabled: a.
5. Maintenance 3-2018 d. Reinsert and fully seat the dipstick. e. Remove the dipstick and check the oil level. NOTICE The engine oil level indicated on the dipstick should be between the High (15 qt [14.2L]) and Low (13 qt [12.4L]) marks. f. Reinsert and fully seat the dipstick. If the engine oil level check shows excessive or insufficient levels of oil (that is, oil level line above the High mark or below the Low mark), oil must be drained or added.
3-2018 5. Maintenance Draining Oil If the oil level is found to be excessive, oil must be drained from the engine. 1. Detach the oil drain hose from the side of the engine. 2. Place the end of the drain hose into an appropriate container. Refer to local regulations to determine the appropriate container for used oil. • Open the oil drain valve to release oil from the engine into the appropriate container. • Recheck the engine oil level. Based on the results, add or drain oil.
5. Maintenance 3-2018 NOTICE Cummins highly recommends that any service or maintenance work be performed by qualified technicians. 1. Before changing the oil, the generator set should be operated until the water temperature is approximately 60 °C (140 °F). 2. 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.
3-2018 5. Maintenance 13. Dispose of the used oil and oil filter according to local environmental regulations. 5.5 Air Intake System The direct flow air cleaner consists of a primary filter and a secondary filter within the air cleaner housing. The air cleaner has been designed for a maximum restriction, at which point the filter elements should be changed. Refer to the Model Specifications section.
5. Maintenance 3-2018 No. 1 Description No. Air Cleaner FIGURE 39. 2 Description Strap Clamp EXAMPLE OF NORMAL DUTY AIR CLEANER Heavy Duty Air Cleaner Element Replacement CAUTION Holes, loose-end seals, dented sealing surfaces, corrosion of pipes, and other forms of damage render the air cleaner inoperative and require immediate element replacement or engine damage can occur. NOTICE Cummins Inc. does not recommend cleaning paper-type air cleaner elements. 1.
3-2018 5. Maintenance d. Turn the end cover (4) clockwise until the latch (3) snaps into place. No. Description No. Description 1 Housing 3 Latch 2 Air Filter Element 4 End Cover FIGURE 40. 5.6 EXAMPLE OF HEAVY DUTY AIR CLEANER 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 3-2018 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. Safety Precautions Servicing of batteries are to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.
3-2018 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 3-2018 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.
3-2018 5. Maintenance 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. Always replace the starting battery with the same number and type (e.g.
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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 3-2018 3. Air intake restriction above specification a. Inspect air filter for obstruction. Replace if necessary. 6.4 Code 143 - Engine Oil Pressure Low (Warning) Logic: Engine oil pressure is below the low oil pressure warning threshold. Possible Causes: 1. Lubricating oil level is low 2. External leak Diagnosis and Repair: 1. Lubricating oil level is low a. Check the oil level. Add oil, if necessary. 2. External leak a. Inspect the engine and surrounding area for external oil leaks.
3-2018 6. Troubleshooting 3. Coolant level below specification a. Check coolant level. b. Add coolant if applicable. 4. Blocked radiator a. Inspect for dirt, debris, or obstruction. b. Remove blockage or winterfront if applicable. 5. Enclosure air discharge blocked a. Inspect for dirt, debris, or obstructions. b. Remove blockage or snow/ice buildup if applicable. 6. Broken or loose fan belt a. Inspect belt(s) for damage, wear, and proper tension. b. Repair or replace belt(s) if damaged or worn. 6.
6. Troubleshooting 6.8 3-2018 Code 415 - Engine Oil Pressure Low (Shutdown) Logic: Engine oil pressure is below 26 psig (180 kpa) for greater than 10 seconds. Possible Cause: 1. Lubricating oil level is low 2. External leak Diagnosis and Repair: 1. Lubricating oil level is low a. Check the oil level. Add oil, if necessary. 2. External leak a. Inspect the engine and surrounding area for external oil leaks. b. Contact your local dealer if a leak is present. 6.
3-2018 6. Troubleshooting 6.10 Code 488 - Intake Manifold Temperature High (Warning) Logic: The engine intake manifold temperature has exceeded the temperatures below for more than 90 seconds: • Models C45 N6, C50 N6 and C60 N6: 158 °F (70 °C) • Models C70 N6, C80 N6 and C100 N6: 167 °F (75 °C) Possible Causes: 1. High ambient temperature 2. Enclosure air intake blocked 3. Coolant level is below specification 4. Radiator blocked 5. Enclosure air discharge blocked 6.
6. Troubleshooting 3-2018 6.11 Code 1438 - Fail to Crank (Shutdown) Logic: The engine failed to crank after the generator control received a start signal. Possible Cause: 1. Dead or weak battery 2. Failed starter Diagnosis and Repair: 1. Dead or weak battery a. Verify battery voltage is at least 12 VDC (or 24 VDC if applicable). b. Charge or replace the battery as necessary. 2. Failed starter a. Press the Reset/Fault acknowledge button on the display. b.
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