CUMMINS C13N6H, C17N6H, C20N6H, C20N6HC Service Manual

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ServiceService ManualManual

Generator Set

Onan Generator Set for Home Standby

C13N6H (Spec A) C17N6H (Spec A) C20N6H (Spec A) C20N6HC (Spec A)

English Original Instructions

6-2017 A053X177 (Issue 6)

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1. IMPORTANT SAFETY INSTRUCTIONS....................................................................................... 1

1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1

1.2 General Information ................................................................................................................ 1

1.3 Generator Set Safety Code .................................................................................................... 4

1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 6

1.5 Fuel and Fumes Are Flammable ............................................................................................ 7

1.6 Exhaust Gases Are Deadly..................................................................................................... 8

1.7 The Hazards of Carbon Monoxide.......................................................................................... 9

1.8 Earth Ground Connection..................................................................................................... 10

2. INTRODUCTION.......................................................................................................................... 11

2.1 About This Manual................................................................................................................ 11

2.2 Test Equipment..................................................................................................................... 12

2.3 Schedule of Abbreviations.................................................................................................... 12

2.4 Related Literature ................................................................................................................. 14

2.5 Model Specifications............................................................................................................. 15

2.6 After Sales Services.............................................................................................................. 18

3. STARTUP .................................................................................................................................... 25

3.1 "Establishing Communications" Message ............................................................................ 25

3.2 "Clock Setup" Screen............................................................................................................ 25

3.3 "Exercise" Screen ................................................................................................................ 31

3.4 "Brightness and Contrast" Screen ........................................................................................ 34

3.5 "About" Screen...................................................................................................................... 36

3.6 "Event Log" Screen............................................................................................................... 38

3.7 "Fault Log" Screen................................................................................................................ 39

3.8 "System Status" Screen........................................................................................................ 40

3.9 "Mode" Screen...................................................................................................................... 41

3.10 Automatic Load Management............................................................................................. 44

3.11 Startup ............................................................................................................................... 44

4. OPERATION................................................................................................................................ 47

4.1 Introduction ........................................................................................................................... 47

4.2 General Operating Conditions .............................................................................................. 47

4.3 Generator Set Operation....................................................................................................... 47

4.4 Manual Start Sequence (Local)............................................................................................ 53

4.5 Manual Stop Sequence (Local) ............................................................................................ 54

4.6 Manual Start/Stop Sequence (Remote)................................................................................ 54

4.7 "Fault" and "New Event" Screens......................................................................................... 54

5. MAINTENANCE........................................................................................................................... 59

5.1 Maintenance Safety .............................................................................................................. 59

5.2 Periodic Maintenance ........................................................................................................... 63

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Table of Contents 6-2017

5.3 Engine Oil ............................................................................................................................. 65

5.4 Exhaust System Maintenance .............................................................................................. 72

5.5 DC Electrical System............................................................................................................ 73

5.6 Batteries................................................................................................................................ 73

5.7 Spark Plugs .......................................................................................................................... 77

5.8 Cleaning the Generator Set Housing.................................................................................... 77

5.9 Complete System Test ........................................................................................................ 77

6. SERVICE...................................................................................................................................... 79

6.1 Control System ..................................................................................................................... 79

6.2 Fuel System.......................................................................................................................... 88

6.3 Cylinder Head Assembly Replacement................................................................................ 96

6.4 Engine Exhaust..................................................................................................................... 99

6.5 Alternator ............................................................................................................................ 100

6.6 Placing the Generator Set Back in Service ....................................................................... 119

6.7 Transfer Switch................................................................................................................... 119

6.8 Line Circuit Breaker Troubleshooting ................................................................................. 120

7. TROUBLESHOOTING............................................................................................................... 121

7.1 Troubleshooting Procedures............................................................................................... 121

7.2 Safety Considerations......................................................................................................... 121

7.3 GATRR Troubleshooting Approach.................................................................................... 122

7.4 Tools and Parts Required................................................................................................... 123

7.5 Troubleshooting with the Local or Remote Displays ......................................................... 124

7.6 Utility-Powered Battery Charger Troubleshooting .............................................................. 124

7.7 Engine Flywheel Battery Charger Troubleshooting ............................................................ 127

7.8 Fuel Shutoff Solenoid Valve ............................................................................................... 129

7.9 Troubleshooting by Symptom............................................................................................. 130

7.10 Troubleshooting with Fault Codes .................................................................................... 134

7.11 Remote Monitoring Communication Troubleshooting....................................................... 157

APPENDIX A. WIRING DIAGRAMS............................................................................................... 165

A.0 Wiring Diagrams................................................................................................................. 166

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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 Warning, Caution, and Note Styles Used in This Manual

The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel, or equipment.

DANGER

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

1.2 General Information

This manual should form part of the documentation package supplied by Cummins with specific generator sets. In the event that this manual has been supplied in isolation please contact your authorized distributor.

It is in the operator’s interest to read and understand all warnings and cautions contained within the documentation relevant to the generator set, its operation and daily maintenance.

CAUTION

NOTICE

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1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

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. All guards must be properly

fastened to prevent unintended contact.

WARNING

Toxic Hazard Used engine oils have been identified by some state and federal agencies to

cause cancer or reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or

changing engine oil. Wear protective gloves and face guard.

WARNING

Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or

death. Do not operate equipment when fatigued, or after consuming any alcohol or

drug. Make sure that only suitably trained and experienced service personnel

perform electrical and/or mechanical service.

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.

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1. IMPORTANT SAFETY INSTRUCTIONS6-2017

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. Clean up coolant spills and dispose of used coolant

in accordance with local environmental regulations.

WARNING

Combustible Liquid Ignition of combustible liquids is a fire or explosion hazard which can cause

severe burns or death. Do not store fuel, cleaners, oil, etc., near the generator set. Do not use

combustible liquids like ether.

WARNING

Combustible Gases Generator sets in operation have combustible gases under pressure, which

if ignited can cause eye and ear damage. Wear appropriate eye and ear protection at all times.

WARNING

Combustible Gases Generator sets in operation have combustible gases under pressure, which

if ignited can cause severe injury. Do not operate the generator set with any doors open.

WARNING

Fire Hazard Materials drawn into the generator set, as well as accumulated grease and

oil, are a fire hazard. Fire can cause severe burns or death. Keep the generator set and the surrounding area clean and free from

obstructions. Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit.

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1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

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. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in the applicable region.)

NOTICE

Before performing maintenance and service procedures on enclosed generator sets, make sure the service access doors are secured open.

NOTICE

Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel, coolant, or exhaust leaks. Do not step on the generator set when entering or leaving the generator set room.

1.3 Generator Set Safety Code

Before operating the generator set, read the manuals and become familiar with them and the equipment. 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.

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.

• 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.

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1. IMPORTANT SAFETY INSTRUCTIONS6-2017

• Make sure that fasteners on the generator set are secure. Tighten supports and clamps; keep guards in position over fans, drive belts, etc.

• Do not wear loose clothing or jewelry in the vicinity of moving parts or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts.

• If any adjustments must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc.

Alternator Operating Areas

WARNING

Ejected Debris Debris ejected during catastrophic failure can cause serious injury or death

by impact, severing or stabbing. To prevent injury:

• Keep away from the air inlet and air outlet when the alternator is running.

• Do not put operator controls near the air inlet and air outlet.

• Do not cause overheating by running the alternator outside rating plate parameters.

• Do not overload the alternator.

• Do not run an alternator with excessive vibration.

• Do not synchronize parallel alternators outside the specified parameters.

Always wear suitable PPE when working in the hatched areas shown in the diagram or directly in-line with any air inlet/outlet.

FIGURE 1. HATCHED AREAS

Make sure this consideration is captured in your risk assessment.

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1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

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. Refer to standard NFPA 70E or equivalent safety standards in corresponding regions for details of the dangers involved and for the safety requirements.

Guidelines to follow when working on de-energized electrical systems:

• Use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards.

• De-energize and lockout/tagout electrical systems prior to working on them. Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment or the release of stored energy. Please refer to the lockout/tagout section for more information.

• De-energize and lockout/tagout all circuits and devices before removing any protective shields or making any measurements on electrical equipment.

• Follow all applicable regional electrical and safety codes.

Guidelines to follow when working on energized electrical systems:

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.

NOTICE

Exposed energized electrical work is only allowed as per the relevant procedures and must be undertaken by a Cummins authorized person with any appropriate energized work permit for the work to be performed while using proper PPE, tools and equipment.

In summary:

• Do not tamper with or bypass interlocks unless you are authorized to do so.

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1. IMPORTANT SAFETY INSTRUCTIONS6-2017

• Understand and assess the risks - use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards.

• Make sure that an accompanying person who can undertake a rescue is nearby.

AC Supply and Isolation

NOTICE

Local electrical codes and regulations (for example, BS EN 12601:2010 Reciprocating internal combustion engine driven generating sets) may

require the installation of a disconnect means for the generator set, either on the generator set or where the generator set conductors enter a facility.

NOTICE

The AC supply must have the correct over current and earth fault protection according to local electrical codes and regulations. This equipment must be earthed (grounded).

It is the sole responsibility of the customer to provide AC power conductors for connection to load devices and the means to isolate the AC input to the terminal box; these must comply with local electrical codes and regulations. Refer to the wiring diagram supplied with the generator set.

The disconnecting device is not provided as part of the generator set, and Cummins accepts no responsibility for providing the means of isolation.

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.

1.5 Fuel and Fumes Are Flammable

Fire, explosion, and personal injury or death can result from improper practices.

• Do not fill fuel tanks while the engine is running unless the tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard.

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1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

• Do not permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank.

• Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent.

• Make sure all fuel supplies have a positive shutoff valve.

• Make sure the battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.

Gaseous Fuels

Natural gas is lighter than air, and will tend to gather under covered areas. Propane is heavier than air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling propane to be trained and qualified.

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. The owners and operators of the generator set are solely responsible for operating the generator set safely. Contact your authorized Cummins distributor for more information.

1.6 Exhaust Gases Are Deadly

• Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas, and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust system daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment.

• 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.

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1. IMPORTANT SAFETY INSTRUCTIONS6-2017

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 Gases Inhalation of exhaust gases can cause asphyxiation and death. Pipe exhaust gas outside and away from windows, doors, or other inlets to

buildings. Do not allow exhaust gas to accumulate in habitable areas.

WARNING

Fire Hazard Contaminated insulation is a fire hazard. Fire can cause severe burns or

death. Remove any contaminated insulation and dispose of it in accordance with

local regulations.

The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position. Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust.

The exhaust pipes may have some insulating covers fitted. If these covers become contaminated they must be replaced before the generator set is run.

To minimize the risk of fire, make sure the following steps are observed:

• Make sure that the engine is allowed to cool thoroughly before performing maintenance or operation tasks.

• Clean the exhaust pipe thoroughly.

1.7 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. Mild effects of CO poisoning include eye irritation, dizziness, headaches, fatigue and the inability to think clearly. More extreme symptoms include vomiting, seizures and collapse.

Engine-driven generator sets produce harmful levels of carbon monoxide that can injure or kill you.

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1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

Special Risks of CO near the Home

WARNING

Toxic Gases Carbon monoxide (CO) gas can cause nausea, fainting, or death. Residents

can be exposed to lethal levels of CO when the generator set is running. Depending on air temperature and wind, CO can accumulate in or near the home.

To protect yourself and others from the dangers of CO poisoning, it is recommended that reliable, approved, and operable CO detector alarms are installed in proper locations in the home as specified by their manufacturer.

Protecting Yourself from CO Poisoning

• Locate the generator set in an area where there are no windows, doors, or other access points into the home.

• Make sure all CO detectors are installed and working properly.

• Pay attention for signs of CO poisoning.

• Check the exhaust system for corrosion, obstruction, and leaks every time you start the generator set and every eight hours when you run it continuously.

1.8 Earth Ground Connection

The neutral of the generator set may be required to be bonded to earth ground at the generator set location, or at a remote location, depending on system design requirements. Consult the engineering drawings for the facility or a qualified electrical design engineer for proper installation.

NOTICE

The end user is responsible to make sure that the ground connection point surface area is clean and free of rust before making a connection.

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.

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2 Introduction

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.

Electrical Generating Equipment Faulty electrical generating equipment can cause severe personal injury or

death. Generator sets must be installed, certified, and operated by trained and

experienced person in accordance with the installation instructions and all applicable codes.

WARNING

2.1 About This Manual

This manual provides troubleshooting and repair information for the generator sets listed on the front cover.

The information contained within the manual is based on information available at the time of going to print. In line with the Cummins Inc. policy of continuous development and improvement, information may change at any time without notice. The users should therefore make sure that before commencing any work, they have the latest information available. The latest version of this manual is available on QuickServe Online (https://quickserve.cummins.com).

This manual does not include instructions for servicing printed circuit board assemblies. After determining that a printed circuit board assembly is faulty, replace it. Do not repair it. Attempts to repair a printed circuit board can lead to costly damage to the equipment.

This manual contains basic (generic) wiring diagrams and schematics that are included to help in troubleshooting. The wiring diagrams and schematics that are maintained with the unit should be updated when modifications are made to the unit.

Operating and basic maintenance instructions are in the applicable generator set operator manual. Read and carefully observe all instructions and precautions in this manual.

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2. Introduction 6-2017

2.2 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. For example, it does not identify units of measure or acronyms that appear only in parameters, event/fault names, or part/accessory names.

Abbr. Description Abbr. Description

AC Alternating Current LED Light-Emitting Diode AMP AMP, Inc. (part of Tyco

Electronics)

ANSI American National

Standards Institute ASOV Automatic Shut Off Valve MPU Magnetic Pickup ASTM American Society for

Testing and Materials

(ASTM International) ATS Automatic Transfer

Switch AVR Automatic Voltage

Regulator AWG American Wire Gauge NO Normally Open CAN Controlled Area Network NWF Network Failure CB Circuit Breaker OEM Original Equipment

MFM Multifunction Monitor

Mil Std Military Standard

NC Normally Closed

NC Not Connected

NFPA National Fire Protection

Agency

Manufacturer CE Conformité Européenne OOR Out Of Range CCA Cold Cranking Ampere OORH/

ORH

Out Of Range High

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Abbr. Description Abbr. Description

CFM Cubic Feet per Minute OORL/ORL Out Of Range Low

2. Introduction6-2017

CGT Cummins Generator

PB Push Button

Technologies CMM Cubic Meters per Minute PCC PowerCommand®Control CT Current Transformer PGI Power Generation

Interface

DC Direct Current PGN Parameter Group

Number DEF Diesel Exhaust Fluid PI Proportional/Integral DPF Diesel Particulate Filter PID Proportional/Integral/

Derivative EBS Excitation Boost System PLC Programmable Logic

Controller ECM Engine Control Module PMG Permanent Magnet

Generator ECS Engine Control System PPE Personal Protective

Equipment EMI Electromagnetic

PT Potential Transformer

Interference EN European Standard PTC Power Transfer Control EPS Engine Protection

PWM Pulse-Width Modulation

System E-Stop Emergency Stop RFI Radio Frequency

Interference FAE Full Authority Electronic RH Relative Humidity FMI Failure Mode Identifier RMS Remote Monitoring

System FSO Fuel Shutoff RMS Root Mean Square Genset Generator Set RTU Remote Terminal Unit GCP Generator Control Panel SAE Society of Automotive

Engineers GND Ground scfh Standard Cubic Feet of

gas per Hour HMI Human-Machine

Interface

SCR Selective Catalytic

Reduction

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2. Introduction 6-2017

Abbr. Description Abbr. Description

IC Integrated Circuit SPN Suspect Parameter

Number ISO International Organization

for Standardization

LBNG Lean-Burn Natural Gas UL Underwriters

LCD Liquid Crystal Display UPS Uninterruptible Power

LCT Low Coolant

Temperature

2.4 Related Literature

Before any attempt is made to operate the generator set, the operator should take time to read all of the manuals supplied with the generator set and familiarize themselves with the warnings and operating procedures.

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.

The Health and Safety manual must be read in conjunction with this manual for the safe operation of the generator set, as well as the Warranty Statements.

SW_B+ Switched B+

Laboratories

Supply

NOTICE

The literature provided with the generator set is as follows:

• Installation Manual (A053X172)

• Operator Manual (A053X174)

• Quick Start Installation Guide (A053X181)

• Quick Start Operator Guide (A053X183)

• Health and Safety Manual (0908-0110-00)

• Global Warranty Statement (A056F206)

• Emission Warranty Statement (Federal Emissions EPA Title 40 CFR Part 90 Component Warranty) (A028X278)

The relevant manuals appropriate to your generator set are also available. The documents below are in English:

• Generator Set Service Manual (A053X177)

• RA Series RA112L1 Automatic Transfer Switch Owner Manual (A052S254) - if applicable

Page 19

• RA Series 100A/200A/400A Automatic Transfer Switch Owner Manual (A046S594) - 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. MODEL VARIATIONS

2. Introduction6-2017

Model

C13N6H Both 13 54.2 C17N6H Both 17 70.8

C20N6H,

C20N6HC

Maximum load imbalance allowed is 50% of generator set rating.

TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS)

Temperature Description

Above 4 °C (40 °F) No starting aids required

-17 to 4 °C (0 to 40 °F) Alternator and regulator heaters (supplied with the generator set)

Natural Gas or

Propane Vapor

Natural Gas Only 18 75

Propane Vapor

Only

kW Amps Frequency Voltage

20 83.3

NOTICE

60 Hz

120/240 VAC Single Phase

Below -17 °C (0 °F)

• Alternator and regulator heaters

• 0W30 oil (see the oil recommendation below)

• Extreme cold weather kit (A045B984) (includes battery and oil heaters)

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2. Introduction 6-2017

TABLE 3. FUEL SPECIFICATIONS (AT FULL LOAD) (ALL MODELS)

C13N6H C17N6H C20N6H, C20N6HC

Type

scfh BTU/hr scfh BTU/hr scfh BTU/hr

Natural Gas 253 260,000 289 297,000 300 309,000 Propane 85 212,000 101 252,000 116 290,000

Natural Gas: 3.5 - 12 inch water column (0.9 - 3.0 kPa)

Fuel Pressure

Propane Vapor: 1.5 - 3.0 kPa (6 - 12 inch water column) Maximum pressure for either fuel under any condition: 3.2 kPa (13

inch water column)

TABLE 4. ENGINE SPECIFICATIONS (ALL MODELS)

Type Value

Engine

2 cylinder v-twin, OHV, air-cooled, 4-stroke, spark

ignited Displacement 999 cc (60.9 in3) Spark Plug Gap 0.7 - 0.8 mm (0.027 - 0.031 in) Spark Plug Torque (Cold Engine) 25 - 30 Nm (18 - 22 ft-lb) RPM 3600 Lubricating Oil Pressure at Rated

Speed (Minimum)

310 kPa (45 psi)

Full synthetic gasoline engine oil which meets or

exceeds API service SN/SN-RC and ILSAC GF-5: Oil Recommendation

• 5W30: Temperatures above -17 °C (0 °F)

• 0W30: All temperatures, required below -17 °C (0 °F)

Lubricating Oil Capacity:

Lubricating Oil Pressure at Rated Speed (Minimum)

310 kPa (45 psi)

--Full at High Mark on Dipstick 2.3 L (2.4 qt)

--Low Mark on Dipstick 1.3 L (1.4 qt)

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Model

2. Introduction6-2017

TABLE 5. GENERATOR SET SIZE (ALL MODELS)

Dimension Value

Length 865 mm (34.1 in) Width 915 mm (36 in) Height 694 mm (27.3 in)

TABLE 6. GENERATOR SET WET WEIGHT (INCLUDING BATTERY)

Model Value

C13N6H 218 kg (479 lb) C17N6H, C20N6H, C20N6HC 241 kg (531 lb)

TABLE 7. GENERATOR SET DERATING GUIDELINES

Engine Power Available Up To... Derate At…

Elevation Ambient Temperature Elevation Temperature

C13N6H 2100 m (6900 ft) 25 °C (77 °F) C17N6H 300 m (1000 ft) 25 °C (77 °F)

C20N6H,

C20N6HC

0 m (0 ft) 15 °C (60 °F)

NOTICE

Derating guidelines: This product's output power is limited by factors such

as BTU content of fuel, ambient temperature, altitude, humidity, engine condition, etc. The derating guidelines are based on properly maintained product, using the appropriate fuel. Derate values are based on expected engine power changes from elevation and temperatures listed.

TABLE 8. ALTERNATOR SPECIFICATIONS (ALL MODELS)

Type Specification

Design Rotating field

Poles 2

3.5% per 300 m

(1000 ft)

1% per

5.5 °C (10 °F)

RPM 3600

Voltage 240

Hz 60

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2. Introduction 6-2017

TABLE 9. CONTROL SPECIFICATIONS (ALL MODELS)

Control

Integrated Microprocessor-Based Engine, Alternator, Transfer Switch Controller

TABLE 10. DC SYSTEM SPECIFICATIONS (ALL MODELS)

Type Value

Nominal Battery Voltage 12 VDC Battery Group 51 R Battery Type Lead Acid Minimum Cold Crank Amps (CCA) 450

2.6 After Sales Services

Cummins offers a full range of maintenance and warranty services.

Maintenance

WARNING

Electrical Generating Equipment Incorrect service or parts replacement can result in severe personal injury,

death, and/or equipment damage. 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. Maintenance tasks should only be undertaken by trained and experienced technicians provided by your Cummins Inc. service provider.

Warranty

For details of the warranty coverage for your generator set, refer to the Global Warranty Statement listed in the Related Literature section.

In the event of a breakdown, prompt assistance can normally be given by factory trained service technicians with facilities to undertake all minor and many major repairs to equipment on site.

Extended warranty coverage is also available. For further warranty details, contact your authorized service provider.

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2. Introduction6-2017

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 Inc. service provider. To locate the service provider, refer to power.cummins.com and select Sales & Service Locator. When contacting the service provider, always supply the complete model, specification, and serial number as shown on the nameplate.

Service Technician Support

For technical support for service technicians, call 1-855-TECH711 (1-855-832-

4711) to reach the Channel One Technical Support Hotline in the United States or Canada. Distributors should contact their Cummins Inc. service contact.

Fuel Information Needed for Service Issue

When servicing is needed on a failed fuel tank, the following questions must be answered and conveyed via the submission of the Technical Support Request form (TSR).

1. Is there an actual confirmed leak?

• Has the rupture basin alarm gone off?

• What Fault Code(s) are present?

• Is the sensor functioning properly?

• Is there visible fuel in the basin or outside the tank (i.e. is there an EPA concern)?

• If so, what is the leak rate?

• Is the fluid fuel and NOT water?

• What is the level of the fuel, in inches, in the tank and basin? A dipstick may be required to obtain an accurate reading.

• Can the leak locale be identified?

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2. Introduction 6-2017

CAUTION

High Pressure Excessive pressurization can rupture tanks or basins which

can result in severe personal injury or death. Remove all liquids before pressure testing. Do not exceed 2

psig when testing a tank or basin.

• Has the tank been previously repaired?

• Is there evidence of physical damage that may be contributing to the leak?

• Pictures may convey a great deal of information and should be considered.

2. What are the CPG and manufacturer's details associated with the tank? Include the following in the Issue:

• CPG part number.

• Manufacturer's part number, model, serial number and date of manufacture.

3. What time frame is required for the needed repair or replacement (i.e. how sensitive of an issue is this with the client and do they have any flexibility in the repair timing)?

• If replacement, has there been an order placed for a new tank?

• If ordered, is it categorized as machine down?

• If not, then please update the order accordingly.

• If an order has been placed, the Issue is to reflect this data (order number) as well.

Obtaining Information Needed for Fuel Tank Service Issues

CAUTION

High Pressure Excessive pressurization can rupture tanks or basins which can result

in severe personal injury or death. Remove all liquids before pressure testing. Do not exceed 2 psig when

testing a tank or basin.

To aid in identifying/isolating the leak or obtaining some of the information needed for Fuel Tank Service Issues:

1. Seal all penetrations/fittings with plugs except for one.

2. For the remaining penetration, fit up a regulated pressure source with a calibrated pressure gauge and a pressure relief valve (set to no more than 2.5 psig).

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2. Introduction6-2017

3. Pressurize the tank or basin to 2 psig and observe for the following:

• For secondary tank (basin) work, spray all exterior weld seams with a soap water solution. Observe the pressure gauge for no change in a 30 minute period and visually observe the exterior seams for bubbling. Results are to be conveyed in the Issue details.

• For the primary fuel tank, spray all exterior weld seams with a soap water solution. Observe the pressure gauge for no change in a 30 minute period and visually inspect the interior of the basin to the maximum extent possible. Results are to be conveyed in the Issue details.

NOTICE

For further questions or concerns regarding the information stated above, please contact (in the following order):

1. Your local Service Manager

2. DFSE-Counterpart

3. The Cummins Distributor Technical Support Line (1-812-377-6517)

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2. Introduction 6-2017

Manufacturing Facilities

Facility Address Phone Numbers

U.S. and CANADA

EMEA, CIS Cummins Inc.

ASIA PACIFIC

Cummins Inc. 1400 73rd Ave. NE Minneapolis, MN 55432 USA

Columbus Avenue Manston Park Manston, Ramsgate Kent CT12 5BF United Kingdom

Cummins Inc. Royal Oak Way South Daventry Northamptonshire NN11 8NU United Kingdom

Cummins Inc. 10 Toh Guan Road #07-01 TT International Tradepark Singapore 608838

Toll Free 1-800-CUMMINS (1-800-286-6467) Phone +1 763-574-5000 Fax +1 763-574-5298

Phone +44 1843 255000 Fax +44 1843 255902

Phone +65 6417 2388 Fax +65 6417 2399

BRAZIL Rua Jati, 310, Cumbica

Guarulhos, SP 07180-900 Brazil

CHINA Cummins Inc.

2 Rongchang East Street, Beijing Economic – Technological Development Area Beijing 100176, P.R. China

INDIA Cummins Inc.

Power Generation Business Unit, Plot No B-2, SEZ Industrial Area, Village-Nandal & Surwadi, Taluka- Phaltan Dist- Satara, Maharashtra 415523 India

LATIN AMERICA

3350 Southwest 148th Ave. Suite 205 Miramar, FL 33027 USA

Phone +55 11 2186 4195 Fax +55 11 2186 4729

Phone 86 10 59023001 Fax +86 10 5902 3199

Phone +91 021 66305514

Phone +1 954 431 551 Fax +1 954 433 5797

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Facility Address Phone Numbers

MEXICO Eje 122 No. 200 Zona Industrial

San Luis Potosi, S.L.P. 78395

Phone +52 444 870 6700 Fax +52 444 824 0082

Mexico

2. Introduction6-2017

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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.

The “establishing communications” message will also be displayed whenever the control is brought out of “sleep” mode by pressing any button on the display. Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power. The 30-minute timer is reset with any button press on the display.

3.2 "Clock Setup" Screen

The Clock needs to be reset whenever the battery power is lost or disconnected, or the control has entered “sleep” mode. Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power. The 30minute timer is reset with any button press on the display.

The optional Remote Monitoring System (RMS) uses the generator set's clock. The clock must be set accurately for the RMS to function properly.

To set up the generator set clock for the current date and time:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Clock. Select the Enter key.

3. Use the arrow keys to set the time and date.

NOTICE

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FIGURE 2. CLOCK SETUP SCREEN

4. Select the Next key to go to the Daylight Savings screen.

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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.

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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).

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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).

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3. Startup 6-2017

FIGURE 6. DAYLIGHT SAVINGS TIME (END TIME SETUP)

9. Keep selecting the Back button to save the settings and return to the main screen.

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3.3 "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.

Exercise settings need to be reset whenever battery power is lost or disconnected, or the control has entered “sleep” mode.

Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power. The 30-minute timer is reset with any button press on the display.

To set up the exercise function:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Exercise. Select the Enter key.

3. Startup6-2017

NOTICE

If the time and date have not been set, a pop-up will appear that says, "Set Valid Date and Time".

3. Use the arrow keys to enable or disable the Crank Exercise feature. Select the Next key to go to the Exercise Time field. See the Exercise Sequences section in the operator manual for more information.

NOTICE

When the Crank Exercise feature is enabled, an exercise command will cause the engine starter to engage and rotate the engine, but will not allow the engine to start. This feature allows the control system to monitor critical generator set systems without running the engine. When Crank Exercise is enabled, the generator set's exercising will alternate between the Crank Exercise sequence and the normal exercise sequence (that is, engine running) at scheduled times.

4. Use the arrow keys to set how long the generator set will exercise (from 1 to 20 minutes). Select the Next key to go to the Exercise field. The Exercise Sched screen appears.

5. Use the arrow keys to set how often the generator set will exercise. The frequency selections are:

• Weekly

• Bimonthly

• Monthly

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3. Startup 6-2017

• Never

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. Select either arrow key to start the Exercise Now function.

NOTICE

Initiating the Exercise Now function will cause the generator set to start immediately and run for the amount of time indicated by the Exercise Time field, or run the Crank Exercise sequence. The ATS does not transfer to generator power during exercise mode. Normally scheduled exercise events will occur after the completion of the immediate exercise event.

8. Keep selecting the Back button to save the settings and return to the Main screen.

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FIGURE 7. EXERCISE SETUP SCREEN

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3.4 "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.

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FIGURE 8. BRIGHTNESS AND CONTRAST SCREEN

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3.5 "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.

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FIGURE 9. ABOUT SCREEN

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3.6 "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. EVENT LOG SCREEN

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3.7 "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.

If there are no faults recorded, the “No Stored Faults" screen will appear.

4. Keep pressing the Back button to return to the Main screen.

3. Startup6-2017

NOTICE

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FIGURE 11. FAULT LOG SCREEN

3.8 "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.

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FIGURE 12. SYSTEM STATUS SCREEN

3.9 "Mode" Screen

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.

When Remote is set to Enabled via the local display, the “Remote On” LED on the front of the display will illuminate indicating that the control will accept start commands from remote displays or remote monitoring systems including a web page or cell phone app.

WARNING

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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. The Standby function cannot be enabled remotely unless the Remote function is on. A manual Start or Stop event will disable the Standby function. (If the manual Stop event is performed at the local display, the Remote mode will also be disabled.)

1. To enable or disable the Remote and Standby modes on the LOCAL display:

a. From any screen, select the Mode key to get to the Mode screen. b. Use the arrow keys to enable or disable the Remote mode. Select the Next

key to go to the next screen.

c. Use the arrow keys to enable or disable the Standby mode.

NOTICE

Whenever Standby is enabled, the Remote mode will also automatically be enabled.

d. Keep pressing the Back button to save the settings and return to the Main

screen.

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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. Keep pressing the Back button to save the settings and return to the Main

screen.

FIGURE 14. MODE SETUP SCREEN (REMOTE DISPLAY)

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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. Once the transfer switch transfers to generator set power, the generator set control will evaluate the total load on the generator set versus a set point programmed into the control (80% of rated).

If the generator set’s total load is below the set point, the generator set control will sequentially add the highest priority managed load every three minutes. Managed loads will continue to be added as long as the size of the next priority load to be added won’t increase total generator set load above the set point. The control measures and stores the size of each managed load in its memory. Load priorities are in the following order:

• Priority #1: load control 1

• Priority #2: load control 2

• Priority #3: load control 3

• Priority #4: load control 4

If the load on the generator set is reduced at any time to below the set point, the control will add the next highest priority managed load in three minutes provided it does not increase the total generator set load above the set point.

If the load on the generator set exceeds 95% of its rating, the generator set control will begin disconnecting the lowest managed priority loads in sequence every second until the load on the generator set is below 95% of its rating.

Priority #1 load is always the first added and the last disconnected; therefore, it should be wired to the managed load deemed most critical to the homeowner. Priority #2 load cannot be added before priority #1 load, nor can it be disconnected before priority #3 or #4, etc.

3.11 Startup

1. Verify that the installation was completed correctly.

2. Read the operator manual. Perform the pre-start checks as instructed.

3. Connect the battery cables to the battery with the positive (+) cable first. Immediately cover the battery post and terminal with the red cover provided on the battery cable.

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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.

NOTICE

Contact your local Cummins service provider if you encounter a fault code.

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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.

4.2 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.

• 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.

4.3 Generator Set Operation

WARNING

Combustible Vapors Do not operate a generator set where there are or can be combustible

vapors. These vapors can be sucked through the air intake system and cause engine

acceleration and overspeeding, which can result in a fire, an explosion, personal injury and extensive property damage.

Correct care of your generator set will result in longer life, better performance, and more economical operation.

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Cummins Inc. 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 Inc. 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. The following sequences are applicable to generator sets connected to a single phase RA series transfer switch.

Auto Start Sequence (with an RA Series Transfer Switch)

NOTICE

Standby Mode must be enabled for Auto Start to execute.

In normal operation, utility power is provided through the transfer switch to the building loads; the generator set is not running.

FIGURE 15. GENSET STOPPED

If utility power is not available (that is, there is a power outage), the following sequence will be executed to connect building load to the generator set, and then reconnect building load back to the utility power when it is available.

1. The generator set starts.

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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.

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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.

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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.

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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.

The following steps will be executed when the programmed exercise day and time are reached or the Exercise Now option is selected and the crank only exercise sequence is run:

a. The generator set engine starter engages and rotates the engine, but

the engine does not start.

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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. CYCLE CRANK

4.4 Manual Start Sequence (Local)

NOTICE

If the utility power supply to the generator set's utility powered battery charger is interrupted, the battery can become discharged due to parasitic loads and the generator set may not start when needed. Whenever utility power is interrupted and the generator set is not in Standby mode for any reason (fuel preservation, etc.), start and run the generator set for 2 hours every 24 hour period when temperatures are above 50 °F (10 °C), or every 9 hour period when temperatures are below 50 °F (10 °C).

The following steps will be executed when Manual Start is used at the local display:

1. If you do not want the ATS to transfer load to the generator set, open the generator set mounted circuit breaker when doing a manual start.

2. From the Main screen, select the START key.

3. A second screen appears notifying the operator that Standby will be disabled. Select the START key again to start the generator set.

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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. GENSET POWER

4.5 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. The generator set will stop immediately and the building load will be transferred to the utility.

2. For normal operation to resume, Standby will need to be enabled. See the section on enabling Standby Mode.

NOTICE

The red STOP button on the Local display, when pressed, will cause both Remote and Standby Modes to be disabled.

4.6 Manual Start/Stop Sequence (Remote)

Remote mode must be enabled on the local display to allow manual start and stop from the Remote display. The manual start and stop sequences are the same for the Remote display and the Local display.

NOTICE

The red STOP button on the Remote display, when pressed, will cause the Standby Mode to be disabled.

4.7 "Fault" and "New Event" Screens

Various fault and event screens may appear on the operator display.

"FAULT" SCREEN

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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.

See the "Fault Log" Screen section of this manual for instructions on viewing the log of the last 20 faults.

“NEW EVENT” SCREEN

A New Event screen appears whenever the system status changes. The screen provides a brief description of the event, the current engine hours, and the date and time of the event. The message remains displayed unless superseded by a new event, or the BACK button is pressed.

1. Operation Events:

FIGURE 27. MANUAL STOP – STANDBY DISABLED

FIGURE 28. STANDBY ENABLED

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FIGURE 29. AUTO STOP – UTILITY RETURNED

FIGURE 30. EXERCISE CYCLE STARTED

FIGURE 31. 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.

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NOTICE

Refer to the Periodic Maintenance Schedule section for more information.

FIGURE 32. SCHEDULED MAINTENANCE REMINDER EXAMPLE

4. Operation6-2017

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.

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5 Maintenance

5.1 Maintenance Safety

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).

Hydrogen Gas Arcing can ignite explosive hydrogen gas given off by batteries, causing

severe personal injury or death. Arcing can occur when cables are removed or replaced, or when the negative (–) battery cable is connected and a tool used to connect or disconnect the positive (+) battery cable touches the frame or other grounded metal part of the generator set.

Insulated tools must be used when working in the vicinity of the batteries. Always remove the negative (–) cable first and reconnect last.

WARNING

Explosive Fumes Arcing can ignite explosive fumes causing severe personal injury or death. Make sure hydrogen from the battery, engine fuel and other explosive fumes

are fully dissipated before working on the generator set.

WARNING

Working at Heights Using the incorrect equipment when working at heights can result in severe

personal injury or death. Suitable equipment for performing these tasks must be used in accordance

with the local guidelines and legislation. Failure to follow these instructions can result in severe personal injury or death.

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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. Voltages are present which can cause electrical shock, resulting in personal injury or damage to equipment.

Isolate all external electrical supplies prior to access of the control panel

NOTICE

Only authorized and qualified maintenance technicians who are familiar with the equipment and its operation should carry out maintenance.

NOTICE

Dependent upon the control system fitted, this unit may operate automatically and could start without warning.

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.

All maintenance tasks must be performed, but be sure to assess them for health and safety risks before starting. For example, perform a task with someone present if doing so will add significantly to the safety of the task.

Read, understand, and comply with all Caution, Warning, and Danger notes in this section, the Important Safety Instructions section, and the documentation supplied with the generator set.

Make sure that adequate lighting is available.

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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. Even if the generator set is put out of service by pressing the Off switch on the Operator Panel (or the STOP button if applicable), the generator set cannot be considered safe to work on until the engine is properly immobilized, as detailed in the following procedure.

NOTICE

Refer also to the engine-specific Operator Manual, if applicable. This manual contains specific equipment instructions that may differ from the standard generator set.

To immobilize the generator set:

1. Press the Off switch from the display and then press the E-Stop button to shut down the engine. This will prevent the starting of the generator set regardless of the Start signal source and will therefore provide an additional safety step for immobilizing the generator set. Alternatively, make sure the generator set is in manual mode (which allows it to be started by manually pushing the buttons).

NOTICE

When the E-Stop button is pressed, the Operator Panel indicates the Shutdown condition by illuminating the red Shutdown status LED

and displaying a message on the graphical LCD display.

2. Thoroughly ventilate the generator set before disconnecting any leads.

3. Turn off and disconnect the heater (where fitted) from the AC source before disconnecting the battery cables.

4. Turn off and disconnect the battery charger (where fitted) from the AC source before disconnecting the battery cables.

5. Turn off the fuel supply to the engine.

6. Disconnect the battery. Disconnect the negative (–) cable first, using an insulated wrench.

7. Place warning notices at each of the above locations that state, "Maintenance in Progress – Immobilized for Safe Working."

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Operating the Generator Set Cover Safely

To configure the local display or access the generator set, you will need to lift the cover (lid). The cover of the generator set is designed to latch securely into the "up" position to prevent accidental closure.

• To open: Lift the cover until the hinge pin drops into the hinge pin slot. Test that the cover is secure by gently pressing down on the cover.

• To close: Lift up on the cover while pressing upward on the hinge pin and slide the pin upwards out of the hinge pin slot. Carefully push the cover downward and let go of the hinge pin allowing it to ride along the hinge until the cover is closed.

FIGURE 35. HINGE LOCATION

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5.2 Periodic Maintenance

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. If the generator set will be subjected to extreme operating conditions, the service intervals should be reduced accordingly.

At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance.

Some of the factors that can affect the maintenance schedule are:

• Extremes in ambient temperature

5. Maintenance6-2017

WARNING

• Exposure to elements

• Exposure to salt water

• Exposure to windblown dust or sand

Consult with your authorized Cummins Inc. service provider if the generator set will be subjected to any extreme operating conditions, and determine if extra protection or a reduction in service intervals is needed. Use the engine hours shown on the system status screen to keep to keep an accurate log of all service performed for warranty support. Perform all service at the time period indicated, or after the number of operating hours indicated, whichever comes first.

Repair or replace worn, damaged, or improperly functioning components identified during periodic maintenance procedures.

Periodic Maintenance Guidelines

Regularly performing the following periodic maintenance tasks greatly reduces the chances of a generator set shutdown:

• Maintain an appropriate oil level.

• Keep battery connections clean and tight.

• Do not overload the generator set.

• Keep the air inlet and outlet openings clear.

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5. Maintenance 6-2017

Periodic Maintenance Schedule

Periodic maintenance is essential for top generator set performance. Use the Maintenance Frequency table below as a guide for normal periodic maintenance.

• In hot and dusty environments, some maintenance procedures should be performed more frequently, as indicated by the footnotes in the table.

• Maintenance, replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual.

◦ Warranty work MUST be completed by your authorized Cummins Inc.

service provider.

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. Disconnect the negative (–) cable from the battery and secure it from

contacting the battery terminals to prevent accidental starting.

NOTICE

Perform all service at the time period indicated, or after the number of operating hours indicated, whichever comes first.

TABLE 11. MAINTENANCE FREQUENCY

Maintenance Frequency

(Running Time)

Maintenance Task

Check Engine Oil Level ■

First 25

Hours and

100 Hours

Every 24

Hours

2, 3

Every 200

Hours

Change Engine Oil and Oil Filter ■ ■ Adjust Engine Valve Clearance ■

1, 6

■

Replace Engine Air Filter ■ Clean and Check Starting Battery ■ Complete System Test ■

1, 6

5, 6

Every 2

Years

■

5, 6

■

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5. Maintenance6-2017

Maintenance Frequency

(Running Time)

Maintenance Task

1. Perform sooner if engine performance deteriorates.

2. Perform more often when operating in high temperature conditions.

3. Check daily during power outages, or monthly without power outages.

4. Perform more often when operating in dusty conditions.

5. See the automatic transfer switch manual for testing of load transfer.

6. Must be performed by a qualified service technician (authorized Cummins Inc. service provider).

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

First 25

Hours and

100 Hours

Every 24

Hours

Every 200

Hours

Every 2

Years

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.

5.3 Engine Oil

Recommended Engine Oil

Check the oil level prior to starting the generator set to verify that the oil level is between the High and Low marks.

The generator set is shipped with 0W30 synthetic engine oil. Refer to the Model Specification section for the oil specification.

Checking Engine Oil Level

State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rubber gloves and wash exposed skin.

WARNING

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5. Maintenance 6-2017

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

Crankcase pressure can blow out hot oil and cause severe burns. Do NOT check oil while the generator set is operating.

NOTICE

Check the engine oil level when the generator set is not running and is out of Remote mode.

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.

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5. Maintenance6-2017

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. ENGINE OIL COMPONENTS (SIDE VIEW)

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5. Maintenance 6-2017

No. Description No. Description

1 Engine Oil Level Dipstick 2 Engine Oil Fill

FIGURE 37. 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. Reinsert and fully seat the dipstick. If the engine oil level check shows excessive or insufficient levels of oil (oil level line

above the High mark or below the Low mark), oil must be drained or added. Refer to the following sections for instructions and guidelines for draining and adding oil.

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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. 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. Refer to the Checking Engine Oil Level section and the Model Specifications section.

3. Recheck the engine oil level. Based on the results, add or drain oil.

4. Clean up and dispose of any oil in accordance with local/state regulations.

Draining Excessive Oil

If the oil level is found to be excessive, oil must first be drained from the engine.

1. Remove the access panels to get to the drain hose.

2. Place the end of the drain hose into an appropriate container.

NOTICE

Refer to local regulations to determine the appropriate container for used oil.

3. Open the oil drain cap to release oil from the engine into the appropriate container.

4. Re-check the engine oil level. Based on the results, add or drain oil.

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5. Maintenance 6-2017

5. When a sufficient amount of oil has been drained from the system, close the oil drain cap.

6. Wipe the oil drain cap clean.

7. Re-install the access panels. Torque the fasteners 3.5 - 5.0 ft-lb (5.0 - 6.6 Nm).

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. Isolate all auxiliary supplies and use an insulated wrench to disconnect the

starting battery cables, negative (–) cable first.

WARNING

Toxic Hazard State and federal agencies have determined that contact with used engine oil

can cause cancer or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rubber gloves and wash

exposed skin.

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 generator set is not running and is out of Remote 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. Open the generator set's circuit breaker to prevent the ATS from transferring to generator set source when manually starting.

2. Before changing the oil, manually start the generator set.

3. Allow the generator set to run for 2 to 5 minutes to warm the engine oil.

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4. Remove the access panels to get to the drain hose.

5. 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. If applicable, 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.

6. Open the oil drain cap to release oil from the engine into the appropriate container.

NOTICE

Refer to local regulations to determine the appropriate container for used oil.

7. Close the oil drain cap.

8. Wipe the oil drain cap clean.

9. Place an appropriate container below the oil filter to collect oil as the filter is being removed.

10. Remove the oil filter by turning it counterclockwise.

11. Remove the old gasket if it remains on the engine.

12. Clean the filter mounting surface on the engine block.

13. Make sure the gasket is in place on the new filter and apply a thin film of clean oil to the gasket.

14. Install the new filter until the gasket just touches the block. Turn it an additional 1/2 to 3/4 turn. Do not over-tighten.

15. Remove the container used to collect oil when removing the oil filter.

16. Add the appropriate amount of oil.

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.

17. Check the engine oil level. Based on the results, add or drain oil.

18. Remove any oil that has spilled on the generator set during this procedure.

19. Make sure the generator set breaker is open.

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.

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5. Maintenance 6-2017

21. Operate the generator set with no load for approximately 5 minutes to check for leaks at the oil filter or oil drain hose.

22. Shut down the generator set, wait 5 minutes, and then confirm that the correct oil level is in the pan.

23. Check for leaks and repair any that are identified.

24. Dispose of the used oil and oil filter according to local environmental regulations.

25. Re-install the access panels. Torque the fasteners 5.0 - 6.6 Nm (3.5 - 5.0 ft-lb).

26. Restore the original generator set settings.

27. Close the generator set breaker.

5.4 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.

Allow these components to cool completely before performing any maintenance tasks.

WARNING

Inhalation of Exhaust Gases Inhalation of exhaust gases can result in serious personal injury or death. Be sure deadly exhaust gas is piped outside and away from windows, doors

or other inlets to buildings. Do not allow to accumulate in habitable areas.

WARNING

Moving Parts. Moving parts can cause severe personal injury or death. Use extreme caution around moving parts, etc.

With the generator set operating, inspect the entire exhaust system visually and audibly including the exhaust manifold, muffler, and exhaust pipe without removing guarding and panels. Check for leaks at all connections, welds, gaskets and joints, and ensure that exhaust pipes are not heating surrounding areas excessively. If any leaks are detected, shut down the generator set (if possible). Contact your authorized dealer and have the leaks corrected immediately.

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5.5 DC Electrical System

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.

1. Check the harness connections. If any harness connections are damaged, contact your service representative.

5. Maintenance6-2017

WARNING

FIGURE 38. CHECK HARNESS CONNECTIONS

2. Check the terminals on the batteries for clean and tight connections. Loose or corroded connections create resistance, which can hinder starting. Clean and reconnect the battery cables if loose, using an insulated wrench. Always disconnect both ends of the negative battery cable. Reconnect one end of the cable to the negative battery terminal and the other end to ground. This will make sure that any arcing will be away from the battery and least likely to ignite explosive battery gases.

3. Check connections at the battery charging alternator.

4. Visually inspect the alternator belt to make sure it is not loose or cracked.

5.6 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.

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5. Maintenance 6-2017

Maintenance free batteries (if supplied with the generator set) need no maintenance for commissioning.

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.

WARNING

Arcing Hazard Laying tools or metal objects across the battery can cause arcing that may

ignite battery gases causing explosions resulting in personal injury. Never lay tools or metal objects across the top of the battery.

WARNING

Electric Shock Hazard Voltages and currents present an electrical shock hazard that can cause

severe burns or death. Use tools with insulated handles to prevent the risk of electric shock.

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.

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5. Maintenance6-2017

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.

WARNING

When putting a battery into service on a generator set, connect the negative lead LAST; when removing the battery, disconnect the negative lead FIRST.

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. Wash spilled electrolyte down with an acid neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbonate of soda (also known as baking soda or sodium bicarbonate) to one gallon (4 liters) of water.

5. Continue to add the bicarbonate of soda solution until the evidence of reaction (that is, foaming) has stopped.

6. Flush the resulting liquid with water and dry the area.

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5. Maintenance 6-2017

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.

• Switch a work light on or off away from the battery.

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. Disconnect the negative (–) cable from the battery and secure it from contacting the battery terminals to prevent accidental starting.

4. Once work is complete, reconnect the negative (-) battery cable last.

Replace the battery charger if the battery keeps running down. 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.

NOTICE

If the battery needs to be replaced, make sure that the replacement battery specifications match those found in the Model Specifications in this manual.

Charging

Where a consistent source of AC power is available, Cummins recommends the use of a battery charger to maintain battery condition and charge. Cummins offers several battery chargers.

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5. Maintenance6-2017

Where generator sets are used infrequently and a consistent source of AC power is not available, battery recharging must be put on a monthly recharge schedule to ensure that a fully charged condition is maintained.

NOTICE

NEVER allow a battery to become completely flat (fully discharged), or to stand in a discharged condition, or damage will result.

Follow the battery charger operating instructions for proper use.

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., vented, lead acid, maintenance free) as listed in the specifications section of this document. Properly dispose of battery in accordance with local environment agency requirements.

Always use correct handling techniques to lift and move a battery.

5.7 Spark Plugs

Spark plugs are designed to last the useful life of the generator set. If a spark plug malfunction is suspected, remove and inspect the condition of each spark plug. Check for excessive corrosion, oil accumulation and soot deposits. Refer to the Model Specifications section for spark plug torque.

5.8 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.

5.9 Complete System Test

NOTICE

Only authorized and qualified maintenance technicians who are familiar with the equipment and its operation should carry out this test.

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A complete system test is recommended to verify that the electrical system is working properly. Testing the system once every 200 hours or every 2 years is required to make sure the transfer switch will transfer the load to the generator set if there is a utility power failure. For more information, see the transfer switch owner manual.

To initiate a complete system test:

1. Before starting:

• Check the oil level.

• Make sure there is enough fuel.

• See the Checklist section in the installation manual.

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. Once the transfer switch is connected to utility power, after approximately 5

minutes, the generator set stops.

NOTICE

If the test fails, call your authorized Cummins service provider to fix the problem.

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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.

"Establishing Communications" Message

NOTICE

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6. Service 6-2017

Control Components

No. Description No. Description

1 B+ Battery Cable 7 Control Board 2 Battery Charger 8 Fuel Shut-Off Valves 3 Local Display 9 Circuit Breaker 4 Oil and Battery Heater Temperature

Switch 5 Current Transformers 11 Alternator Temperature Switch 6 Governor Actuator

FIGURE 39. CONTROL COMPONENTS

10 Battery

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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

Connections Optional Ethernet connections are through a Cat 5a or 6 Ethernet cable

Mounting The generator set control is mounted on the engine end of the generator

Configuration Perform the instructions in the "Generator Config" Screen section when

Control Board

Replacement

Control

Software

Updates

When a transfer switch without a built-in controller is used, all transfer and retransfer signals come from the generator set control. Transfer times are pre-set and not adjustable:

• Power transfer delay from the utility to the generator set is set at 1 second.

• Retransfer delay back to the utility is set for five minutes. (After retransfer, there is a generator set cool down period of five minutes.)

connector. Refer to the appropriate wiring diagrams and wiring harness drawings.

set.

replacing the control board. See the Control Board Replacement section.

1. Disconnect the harness to the local display at J1 before updating the control software. Refer to the appropriate wiring diagrams for more information.

2. Connect the InPower Power Generation service tool (PN A044M377) to service connector J5.

3. Press the Stop button to wake up the control.

4. Connect InPower and update the software.

5. Disconnect the service tool harness and reconnect the local display to J1.

Display Setup

The HMI Type screen is used to modify the display and user preferences. A display can be set up to be Local or Remote (default = Remote).

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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. Press and hold the NEXT key down for at least 5 seconds to view the Config Menu.

3. Use the arrow keys to highlight "HMI Type" and click the Enter key. The HMI Type screen appears.

4. In the Display field, select Local or Remote.

5. Keep selecting the Back button to save the settings and return to the Main screen.

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FIGURE 40. 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.

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6. Service 6-2017

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

20 C20N6H,

C20N6HC 21 C17N6H 22 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).

NOTICE

The Rating field is not configurable by the user. Instead, it will be automatically populated based on the Config and Fuel Type field selections.

NOTICE

When converting the generator set to liquid propane, be sure to adjust the manual fuel selector to the LP setting:

a. Use a 6 mm external hex wrench to rotate the center section of the

fuel valve. b. Turn the center section clockwise until the detent is reached. c. When you reach the detent, the required force to turn the valve will

increase significantly - do not rotate center section of valve beyond

this point.

6. Keep selecting the Back button to save the settings and return to the Main screen.

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FIGURE 41. GENERATOR CONFIG SCREEN

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.

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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. Open the hood and make sure the hood latch drops into place.

3. Remove the control access panel. See the Control Components section for locations.

4. Remove all wiring harness plugs from the control board, P1, P2, and the optional Ethernet cord.

5. Remove the bolt retaining the control board.

6. Remove and replace the control board.

7. Re-install the 2 wiring harness plugs P1 and P2 only. Do not reconnect the optional Ethernet cord until you have entered the generator set serial number and model number into the control.

8. Reconnect the generator set battery, positive cable first.

9. Enter the serial number and product code from the generator set nameplate:

a. From the Main screen, select Menu. b. Press and hold the Next key on the Menu screen for at least five seconds

to view the Config Menu. c. Press the Next key to get to the next page. d. Highlight “Nameplate Config” and press the Enter key. e. Manually enter the serial number and model number from the generator set

nameplate.

NOTICE

The model number must be in the 8-digit "A054_###" format.

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FIGURE 42. MENU SCREEN

10. Set the generator output and fuel type in the Generator Config screen, as described in the Generator Config screen section.

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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 Adjustments

NOTICE

Read the warranty statement provided with the generator set for US Environmental Protection Agency (EPA) restrictions on servicing specific components.

Fuel System Components

The generator set's fuel system consists of the following:

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TABLE 12. FUEL SYSTEM COMPONENTS

6. Service6-2017

No. Description No. Description

1 Governor Actuator 5 Fuel Select Valve 2 Intake Manifold 6 Fuel Hose 3 Fuel Shutoff Solenoid Valves (2) 7 Air-Fuel Mixer 4 Fuel Pressure Demand Regulator

Fuel Pressure Requirements

The minimum pressure refers to supply pressure under rated load (maximum gas flow).

See the Model Specifications section for the maximum permissible fuel supply pressure for propane vapor and natural gas.

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6. Service 6-2017

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. To change the generator set control's fuel type from natural gas to liquid propane vapor:

a. From the Main screen, select Menu. b. Press and hold the Next key on the Menu screen for at least 5 seconds to

view the Config Menu.

c. Use the arrow keys to highlight "Config" and click the Enter key. The

Generator Config screen appears.

d. 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).

NOTICE

Do not change the number in the Config field.

NOTICE

The Rating field is not configurable by the user. Instead, it will be automatically populated based on the Config and Fuel Type field selections.

e. Keep selecting the Back button to save the settings and return to the Main

screen.

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FIGURE 43. GENERATOR CONFIG SCREEN

2. Adjust the manual fuel selector to the LP setting:

a. Use a 6 mm external hex wrench to rotate the center section of the fuel

valve. b. Turn the center section clockwise until the detent is reached. c. When you reach the detent, the required force to turn the valve will

increase significantly - do not rotate center section of valve beyond this

point.

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FIGURE 44. LOCATION OF FUEL SELECTOR VALVE

No. Description No. Description

1 Natural Gas Fuel Position 2 Liquid Propane Vapor Fuel Position

FIGURE 45. MANUAL FUEL SELECTOR

Fuel Shutoff Solenoid Troubleshooting

If the generator set does not start, first determine if both valves are in good condition before adjusting the fuel system.

1. Disconnect the four harness leads from the fuel solenoid coils.

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2. Check that battery voltage is being supplied through the generator set harness, using a multi-meter to measure DC voltage between:

• A pair of leads removed from one coil (FSOL1+ and FSGND1)

• A pair of leads removed from the remaining coil (FSSOL2+ and FSGND2) while trying to start the generator set

NOTICE

There must be sufficient battery power available to engage the starter and rotate the engine).

Verify that the voltage is 10.2 VDC:

• If no voltage is measured, check for bad wiring.

• If the voltage is less than 10.2 VDC, check for bad wiring or a discharged battery.

• If the voltage is greater than 10.2 VDC, check for proper solenoid operation.

3. Check for proper solenoid operation. a. While holding onto the solenoid, apply 12 VDC to a coil on one of the

solenoids. b. Listen and feel for the solenoid to activate. c. Repeat applying the voltage a few times to be sure the solenoid operates. d. Repeat these steps for all solenoids. e. If either solenoid does not activate, replace the gas valve assembly.

4. Check for fuel leaks at the solenoid. With a soapy water solution, check pipe threads and areas around the base of the solenoid for gas leakage.

• If a pipe thread is showing bubbles, tighten the pipe connection.

• If anywhere on the gas valve shows bubbles or leakage, replace the complete gas valve assembly.

Air-Fuel Mixer

1. When reinstalling the air-fuel mixer, make sure to assemble the components in the appropriate order, with three new flange gaskets.

2. Torque the flange bolts to 13 ft-lb (17.5 Nm).

Governor Actuator Removal and Installation

GOVERNOR ACTUATOR REMOVAL

1. Shut off AC power to the generator set accessories.

2. Open the generator set breaker.

3. Before disconnecting the generator set battery, note the exercise schedule settings.

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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. Disconnect the battery charger and display electrical plugs.

7. Remove the control access panel. See the figure in the Control Components section.

8. Disconnect the electrical leads.

9. Remove and retain the clip that holds the socket on the ball.

10. Remove the 2 mounting bolts from the bracket.

11. Remove the governor actuator.

GOVERNOR ACTUATOR INSTALLATION

1. Attach the governor actuator and mounting bolts to the actuator bracket.

2. Assemble the governor linkage with the components bottomed out.

a. Loosely install the upper jam nut onto the male threads of the pivot joint. b. Bottom out the ball socket on the male threads of the pivot joint. c. Loosely place the lower jam nut onto the actuator arm. d. Bottom out the pivot joint on the male threads of the actuator arm.

3. Install the governor linkage assembly in the generator set.

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No. Description No. Description

1 Ball Socket 3 Pivot Joint 2 Upper Jam Nut 4 Lower Jam Nut

FIGURE 46. GOVERNOR LINKAGE ASSEMBLY

4. Increase the length of the linkage until the gap between the throttle stop screw and the throttle shaft bracket is 0.25-0.30 mm (0.001 in). Adjust both the ball socket and pivot joint equally.

5. Verify that the mixer arm can be moved (with the linkage installed) to the fully open position.

6. Tighten the jam nuts against the base of the ball socket (1) and the base of the pivot joint (3), as shown in Figure 46.

7. Connect the electrical leads from the wiring harness to the governor actuator.

8. Install the control access panel.

9. Connect the generator set battery and reset the display settings.

10. Turn on AC power to the generator set accessories.

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11. Test run the generator set for 5 minutes with no load.

12. Close the generator set breaker.

6.3 Cylinder Head Assembly Replacement

Parts required:

• Cylinder head assembly

• Cylinder head gasket

• Valve cover gasket

Tools required:

• General mechanical tools

Procedure:

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. 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.

5. Remove rocker arms, rotating the engine first to ensure there is no valve spring pressure on the rocker arm you are removing.

6. Remove the six cylinder head bolts and the cylinder head. Make sure to retain the two cylinder locating sleeves from each cylinder head. See the figure below.