Operator Manual Generator Set QSJ2.4 Engine with 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 7-2018 5.5 Generator Set Output - AC Electric System Checks ............................................................ 5.6 DC Electrical System ............................................................................................................ 5.7 Batteries................................................................................................................................ 5.8 Spark Plugs ...............................................................................
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 7-2018 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.
-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 7-2018 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.
7-2018 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 7-2018 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.
7-2018 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 7-2018 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.
7-2018 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 7-2018 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 7-2018 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. Abbr.
7-2018 2. Introduction Abbr. Description Abbr.
2. Introduction 7-2018 Abbr. 2.4 Description LCD Liquid Crystal Display LCT Low Coolant Temperature Abbr. UPS Description Uninterruptible Power Supply Related Literature The literature provided with the generator set is as follows: • Installation Manual (A045R241) • Operator Manual (A045R242) CAUTION A generator set must be operated and maintained properly if you are to expect safe and reliable operation. The Operator Manual includes a maintenance schedule and a troubleshooting guide.
7-2018 2.5 2. Introduction Model Specifications TABLE 1. 2.4L MODEL VARIATIONS Models Description C20 N6, C22 N6, C25 N6, C30 N6, C36 N6, C40 N6 60 Hz, 1800 RPM C30 N6H, C36 N6H, C40 N6H, C45 N6H, C50 N6H, C60 N6H 60 Hz, 3600 RPM TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS) Temperature Description Battery Type Group Above 4 °C (40 °F) No starting aids required. Standard 26 -17 to 4 °C (0 to 40 °F) Additional coolant heater and battery charger recommended for starting.
2. Introduction 7-2018 TABLE 4. FUEL SPECIFICATIONS 60 HZ, 3600 RPM C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H Full Load (Propane) 195.5 scfh 490,000 BTU/hr 219.6 scfh 550,000 BTU/hr 236.2 scfh 595,000 BTU/hr 256.9 scfh 645,000 BTU/hr 289.5 scfh 725,000 BTU/hr 324.6 scfh 820,000 BTU/hr Full load (Natural Gas) 476.1 scfh 495,000 BTU/hr 533.3 scfh 555,000 BTU/hr 573.2 scfh 595,000 BTU/hr 623.0 scfh 645,000 BTU/hr 704.7 scfh 730,000 BTU/hr 814.
7-2018 2. Introduction TABLE 7. Sound Level 1 (Wet) GENERATOR SET WEIGHT 60 HZ, 1800 RPM C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 C40 N6 kg 503 503 520 580 615 646 lb 1109 1109 1147 1279 1356 1424 TABLE 8. Sound Level 1 (Wet) GENERATOR SET WEIGHT 60 HZ, 3600 RPM C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H kg 514 567 635 635 635 648 lb 1134 1249 1399 1399 1399 1429 TABLE 9.
2. Introduction 7-2018 C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H 120/240 120/208 277/480 3-Phase NOTICE Maximum I2 = 8%. Copyright © 2018 Cummins Inc.
7-2018 2. Introduction TABLE 11. GENERATOR SET DERATING GUIDELINES Engine Power Available Up To... Fuel Elevation Ambient Temperature C20 N6 NG, LP 1005 m (3300 ft) 40 °C (104 °F) C22 N6 NG 670.
2. Introduction 7-2018 TABLE 13. DC SYSTEM SPECIFICATIONS (ALL MODELS) Specification Value Nominal Battery Voltage 12 VDC Battery Group 26 standard, 34 high capacity (a high capacity battery requires an accessory battery tray) Battery Type Maintenance free Minimum Cold Crank Amps 545 standard, 850 high capacity (a high capacity battery requires an accessory battery tray) 2.6 After Sales Services Cummins offers a full range of maintenance and warranty services.
7-2018 2. Introduction 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 For parts, service, and product information, contact the nearest authorized Cummins Inc. dealer. To easily locate the nearest certified distributor/dealer for Cummins generator sets in your area, or for more information, contact us at 1-800CUMMINSTM (1-800-286-6467) or visit www.cummins.com/support.
2. Introduction 7-2018 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.
7-2018 Facility MEXICO 2. Introduction Address Eje 122 No. 200 Zona Industrial San Luis Potosi, S.L.P. 78395 Mexico A045R242 (Issue 12) Phone Numbers Phone +52 444 870 6700 Fax +52 444 824 0082 23 Copyright © 2018 Cummins Inc.
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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 7-2018 FIGURE 1. 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 14. 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).
7-2018 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 15. 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 7-2018 FIGURE 2. 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 16. 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.
7-2018 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 17. 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 7-2018 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 a single phase 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.
7-2018 3. Control System FIGURE 3. A045R242 (Issue 12) CLOCK/EXERCISER MENU NAVIGATION 31 Copyright © 2018 Cummins Inc.
3. Control System 7-2018 Updating Exercise Frequency (1-Phase ATS) NOTICE Not applicable without a single phase 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.
7-2018 3. Control System FIGURE 4. EXERCISE FREQUENCY NAVIGATION Updating Exercise Duration (1-Phase ATS) NOTICE Not applicable without a single phase 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 7-2018 • Press Save to save any changes. After saving, the Save button changes to the Adjust button. FIGURE 5. 3.4 EXERCISE DURATION NAVIGATION Time Setup (1-Phase ATS) NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without a single phase 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.
7-2018 3. Control System • Press Save to save any changes. After saving, the Save button changes to the Adjust button. FIGURE 6. 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.
3. Control System FIGURE 7. 7-2018 "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 20.
7-2018 3. Control System FIGURE 8. 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 21.
3. Control System 7-2018 FIGURE 9. 3.5 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.
7-2018 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 10. A045R242 (Issue 12) BRIGHTNESS AND CONTRAST SCREEN NAVIGATION 39 Copyright © 2018 Cummins Inc.
3. Control System 7-2018 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%. 3.6 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.
7-2018 3. Control System FIGURE 11. A045R242 (Issue 12) HISTORY/ABOUT MENU 41 Copyright © 2018 Cummins Inc.
3. Control System 3.7 7-2018 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.
7-2018 3. Control System FIGURE 12. A045R242 (Issue 12) FAULT LOG SCREEN 43 Copyright © 2018 Cummins Inc.
3. Control System 3.8 7-2018 Operating Modes The generator set's PowerCommand® control has Manual Run, Off, and Auto operating modes that are available from the operator panel. Off Mode When in the Off mode, the control does not allow the generator set to start. If the generator set is running in either Manual Run or Auto mode and the Off button is pressed, the control immediately stops the generator set, and the control transitions to the Off mode. Pressing the Off mode button resets all active faults.
7-2018 3. Control System 3. If the Mode Change Access Code menu is enabled, the Mode Change Access Code is displayed. Enter the Mode Change Access Code. 4. A menu with alternating arrows is displayed above a second symbol. 5. Press the second Manual Run button, and the generator set will now begin the Manual start sequence. The Operator menu that was displayed before Manual Run mode was selected is re-displayed, but with the out. symbol blacked NOTICE To disable Manual Run mode, press the Off button.
3. Control System 7-2018 No. Description No. Description 1 Menu Displayed Only When the Mode Change Access Code Feature Is Enabled 2 Alternating Arrows Displayed FIGURE 13. Copyright © 2018 Cummins Inc.
7-2018 3. Control System 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 14 on page 48), 1. Ensure that it is safe to do so before proceeding to change the mode. 2.
3. Control System 7-2018 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 14. Copyright © 2018 Cummins Inc.
7-2018 3. Control System 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. Control System 7-2018 No. Description 1 No. Description Off Button 2 FIGURE 15. Copyright © 2018 Cummins Inc.
4 Operation 4.1 Safety Considerations WARNING Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Make sure that only personnel who are trained and qualified to work on this equipment are allowed to operate the generator set and perform maintenance on it. WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death.
4. Operation 7-2018 NOTICE Always disconnect a battery charger from its AC source before disconnecting the battery cables. Failure to do so can result in voltage spikes high enough to damage the DC control circuits of the generator set. NOTICE Ventilate the battery area before working on or near the battery. Wear goggles. Stop the generator set and disconnect the battery charger before disconnecting the battery cables using an insulated wrench.
7-2018 4. Operation Exercise Period Generator sets on continuous standby must be able to go from a cold start to being fully operational in a matter of seconds. This can impose a severe burden on engine parts. Regular exercising keeps engine parts lubricated, prevents oxidation of electrical contacts, and in general helps provide reliable engine starting.
4. Operation 7-2018 • 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. 4.5 Generator Set Operation WARNING Combustible Vapors Do not operate an engine where there are or can be combustible vapors.
7-2018 4. Operation Power Outage Sequence The sequence of operation after a power outage (when the generator set is in Auto Mode) is as follows: 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. The utility power turns off (power outage). 3. One second after the power outage, the transfer switch sends the command to the generator set to start. 4.
4. Operation 7-2018 FIGURE 19. TIME REMAINING UNTIL RE-TRANSFER 8. When the utility power is stable for 5 minutes, the transfer switch switches back to utility power. FIGURE 20. BUILDING LOAD TRANSFER IN PROCESS FIGURE 21. UTILITY POWERING BUILDING LOAD 9. The generator set runs for a 5-minute cooldown and shuts off. FIGURE 22. TIME REMAINING UNTIL STOP 10. Normal operation resumes.
7-2018 4. Operation 2. The Exerciser Scheduler On screen displays every 3 seconds and toggles between the existing Information screen that is displayed for 1 second. FIGURE 23. EXERCISER SCHEDULER SCREEN AND INFORMATION SCREEN TOGGLE - EXAMPLE 3. The transfer switch is not commanded to switch the building load to the generator set. NOTICE The user may navigate to other screens from the Information screens during this duration. No functional keys are active on the Exerciser Scheduler On screen. 4.
4. Operation 7-2018 FIGURE 24. MANUAL START SCREEN, STANDARD OPERATOR PANEL 3. The generator set starts and provides voltage to the transfer switch. 4. The generator set provides a signal to the transfer switch to transfer the building load to the generator set. FIGURE 25. BUILDING LOAD TRANSFER IN PROCESS 5. The transfer switch switches the generator set power to the building load. The building is now running on generator power. Copyright © 2018 Cummins Inc.
7-2018 4. Operation FIGURE 26. GENERATOR SET POWERING BUILDING LOAD 6. Press the Off button to switch the load back to the utility power. FIGURE 27. BUILDING LOAD TRANSFER IN PROCESS FIGURE 28. UTILITY POWERING BUILDING LOAD 7. Normal operation resumes. 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 7-2018 FIGURE 29. HMI211 SET IN AUTO MODE 3. Manually start the generator set via the in-home operator panel. Copyright © 2018 Cummins Inc.
7-2018 4. Operation 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. A045R242 (Issue 12) 61 Copyright © 2018 Cummins Inc.
4. Operation 7-2018 FIGURE 32. BUILDING LOAD TRANSFER IN PROCESS 6. The transfer switch switches the generator set power to the building load. The building is now running on generator power. FIGURE 33. GENERATOR SET POWERING BUILDING LOAD 7. When the remote display Stop button is pressed, the transfer switch switches back to utility power after a 5 minute retransfer delay. FIGURE 34. BUILDING LOAD TRANSFER IN PROCESS FIGURE 35. UTILITY POWERING BUILDING LOAD 8.
7-2018 4. Operation FIGURE 36. TIME REMAINING UNTIL STOP 9. Normal operation resumes. A045R242 (Issue 12) 63 Copyright © 2018 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 7-2018 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.
7-2018 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 7-2018 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.
7-2018 5. Maintenance Periodic Maintenance Schedule NOTICE Perform maintenance tasks as specified using the period of operation that occurs first. TABLE 22. Maintenance Item Daily or After 24 Hours Check air cleaner restriction indicator (where fitted): If the service indicator shows red, replace air cleaner elements and reset the air cleaner service indicator. ■ Check air intake system for leaks: Visually inspect the air intake system for signs of wear or damage.
5. Maintenance Maintenance Item 7-2018 Daily or After 24 Hours Check coolant level of radiator(s) (water jacket & LTA): If low, top up to coolant system specifications level, with Cummins recommended coolant mix. ■ Check cooling fan blades: Visually inspect the fan blades through the guarding for signs of wear or damage. ■ Check drive belt, condition and tension: Visually check belt for evidence of wear or slippage.
7-2018 Maintenance Item 5. Maintenance Daily or After 24 Hours Verify that the coolant heater has power and is running (where fitted). Check for evidence of leaks. Remove any corrosion from fittings. ■ Check engine oil level: If low, top up to engine specifications level, with recommended oil. ■ Check fuel lines and hoses: Visually check for leaks, worn or damaged hoses. ■ Check charge alternator: Check visually and audibly when the generator set is running.
5. Maintenance Maintenance Item Check generator set enclosure: Visually check enclosure, walk around inspection of generator set. Make sure no inlets/outlets are covered/restricted, service access doors are operational and safety systems are in place and operational.
7-2018 Maintenance Item 5. Maintenance Daily or After 24 Hours Weekly or After 50 Hours 100 Hours 1 Year or After 200 Hours1 Check water pump for leaks. Check weep holes for evidence of leaks. Replace if leaking. ■ Check engine ground. Clean as necessary. ■ Check engine mounts general condition and for signs of excessive wear. ■ Check starting motor for general condition, wiring connections. ■ Check turbocharger (where fitted) for signs of leakage.
5. Maintenance Maintenance Item 7-2018 Daily or After 24 Hours Weekly or After 50 Hours 100 Hours 1 Year or After 200 Hours1 Check electrical connections (battery, starter motor, alternator connections). Check for tight connections, general condition and remove any corrosion. ■ Check alternator heater (where fitted). Check general condition and wiring connections. ■ Check battery heater (where fitted). Check general condition and wiring connections. ■ Replace cooling system coolant.
7-2018 Date 5. Maintenance Engine Hours Meter Reading Maintenance or Service Performed Record the name, address, and phone number of your authorized Cummins Inc. service center: Name Address Phone Exercising the Generator Set NOTICE Audible engine RPM variation may be heard when there is no load applied. This is normal and does not affect the generator set performance. Exercising the generator set drives off moisture, relubricates the engine, and removes oxides from electrical contacts.
5. Maintenance 7-2018 The generator set exerciser mode defaults are as follows. • Day: Tuesday • Time: 2:00 pm • Period: Monthly • Run Time: 5 minutes Refer to the Exercise Settings section of this manual for more information on setting up the exerciser. 5.3 Engine Oil Recommended Engine Oil Check the oil level prior to starting the generator set to verify that the oil level is between the High and Low marks. The generator set is shipped with engine oil (5W30 API SM or newer engine oil is recommended).
7-2018 5. Maintenance No. Description No. Description 1 Fill Cap 3 Oil Filter 2 Dipstick 4 Oil Drain Hose FIGURE 37. ENGINE OIL COMPONENTS To check the engine oil level: 1. Make sure that the engine has not been running for approximately five minutes. 2. Clean off the area surrounding the dipstick port to prevent entry of debris into the oil pan. 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.
5. Maintenance No. 1 7-2018 Description No. High Oil Level (4.3 L or 4.5 qt) FIGURE 38. 2 Description Low Oil Level (3.8 L or 4.0 qt) ENGINE OIL DIPSTICK 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.
7-2018 5. Maintenance NOTICE Too much oil can cause high oil consumption. Too little oil can cause severe engine damage. Keep the oil level between the High and Low marks on the dipstick. Adding Oil If the oil level is found to be insufficient, oil must be added. 1. Ensure that the oil fill cap area is clean, and prevent debris from entering the engine. 2. Add the appropriate amount of oil, based on the engine oil level check.
5. Maintenance 7-2018 NOTICE If the oil and/or oil filter are not reused, dispose of them in accordance with local environmental regulations. NOTICE Change the engine oil and filter when the engine is not running and is out of Auto mode. NOTICE Change the oil more often in hot and dusty environments. NOTICE Cummins highly recommends that any service or maintenance work be performed by qualified technicians. 1.
7-2018 5.4 5. Maintenance 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 7-2018 No. 1 Description No. Air Cleaner FIGURE 39. 2 Description Strap Clamp EXAMPLE OF NORMAL DUTY AIR CLEANER Heavy Duty Air Cleaner Heavy Duty Air Cleaner Maintenance WARNING Fall Hazard Falls can result in severe personal injury or death. Make sure that suitable equipment for performing tasks at height are used in accordance with local guidelines and legislation.
7-2018 5. Maintenance NOTICE Cummins Inc. does not recommend cleaning paper-type air cleaner elements. 1. To remove the existing air cleaner element: a. Before disassembly, wipe dirt from the cover and the upper portion of the air cleaner. b. Lift the latch (3) and turn the end cover (4) counterclockwise. c. Pull the end cover (4) away from the housing (1). d. Remove the air filter element (2) from the housing (1). e.
5. Maintenance No. 7-2018 Description No. Description 1 Housing 3 Latch 2 Air Filter Element 4 End Cover FIGURE 40. 5.5 EXAMPLE OF HEAVY DUTY AIR CLEANER Generator Set Output - AC Electric System Checks 1. Check the following while the generator set is operating. TABLE 23. AC ELECTRIC SYSTEM CHECKS Check Description Frequency The generator set frequency should be stable and the reading should be the same as the generator set nameplate rating. See the Model Specifications section.
7-2018 5. Maintenance Check AC Ammeter Description At no load, the current readings should be zero. With a load applied, each line current should be similar. Panel Lamps When the operating panel is first connected to the DC supply, the system runs a check by illuminating each of the indicator lamps in turn. 2. If all of the LEDs do not illuminate, replace the operator panel. 5.
5. Maintenance 5.7 7-2018 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. Reference should also be made to the battery manufacturer’s instructions. Maintenance free batteries (if supplied with the generator set) need no maintenance for commissioning.
7-2018 5. Maintenance CAUTION Toxic Hazard Electrolyte is a dilute sulphuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. Wear full eye protection and protective clothing. If electrolyte contacts the skins, wash it off immediately with water. If electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention. Wash spilled electrolyte with an acid neutralizing agent. NOTICE Keep batteries upright to prevent spillage.
5. Maintenance 7-2018 Vented Batteries WARNING Toxic Hazard The electrolyte in vented batteries is a dilute sulfuric acid that is harmful to the skin and eyes. It is also electrically conductive and corrosive. Always: 1. Wear full eye protection and protective clothing; 2. If the electrolyte contacts the skin, wash it off immediately with water; 3. If the electrolyte contacts the eyes, flush them thoroughly and immediately with water and seek medical attention; and 4.
7-2018 5. Maintenance See Battery Charger Maintenance for troubleshooting the charger. Always: • Keep the battery case and terminals clean and dry and the terminals tight. • Remove battery cables with an insulated wrench or battery terminal puller. • Make sure which terminal is positive (+) and which is negative (-) before making battery connections, always removing the negative (-) cable first and reconnecting it last to reduce arcing.
5. Maintenance 7-2018 3. Return the generator set control to the desired setting when finished performing maintenance. 5.9 Cleaning the Generator Set Housing The housing of the generator set housing can be damaged by pressure washing or solvents and other cleaning agents. Only use soap and water or an “all citrus degreaser" to clean the housing. 5.
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 7-2018 • The battery charge condition is satisfactory and the connections are secure • The generator set electrics and alternator connections are secure • The panel connections are secure • The protection circuits have been reset • Blown fuses have been replaced • Tripped contactors or circuit breakers have been reset 6.4 Fault/Status Codes - PowerCommand 1.
7-2018 6. Troubleshooting 2. External leak Diagnosis and Repair: 1. Low lubricating oil level a. Check the oil level. Add or drain 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. Code 151 - Engine Coolant Temperature High (Shutdown) Logic: Engine coolant temperature has exceeded the alarm (shutdown) threshold for high coolant temperature. Possible Cause: 1. High ambient temperature 2.
6. Troubleshooting 7-2018 d. Inspect the radiator cap and gasket for damage and proper pressure operation. i. Contact your local dealer if repair or replacement is required. e. Inspect upper and lower radiator hoses for collapse, distortion, or fluid leaks. i. Contact your local dealer if repair or replacement is required. f. Inspect cooling system components for external contaminates and clean as required. i. Open the radiator cap and inspect for contaminated coolant and scale. ii.
7-2018 6. Troubleshooting b. If a leak is present, contact your Cummins service representative. Code 421 - Engine Oil Temperature High (Warning) Logic: The control has detected the engine oil temperature has exceeded the warning threshold. Possible Cause: 1. High ambient temperature 2. Blocked enclosure air intake 3. Coolant level below specification Diagnosis and Repair: 1. High ambient temperature a. Reduce loads or recirculation of discharge air to generator in elevated ambient. 2.
6. Troubleshooting 7-2018 4. Battery is old and does not maintain a charge • Replace the battery. Code 488 - Intake Manifold Temperature High (Warning) Logic: Engine intake manifold temperature has exceeded 185 °F (85 °C) for more than 90 seconds. Possible Cause: 1. High ambient temperature 2. Enclosure air intake blocked 3. Coolant level is below specification 4. Radiator blocked 5. Enclosure air discharge blocked 6. Fan belt is broken or loose Diagnosis and Repair: 1. High ambient temperature a.
7-2018 6. Troubleshooting 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. Attempt to start the generator and test for B+ at the starter supply lug. c.
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