CUMMINS C 45 N6, C50 N6, C80 N6, C60 N6, C100 N6 Operating Manual

...

Download

Page 1

OperatorOperator ManualManual

Generator Set with QSJ5.9G Engine and PowerCommand® 1.1 Control

C45 N6 (Spec A) C50 N6 (Spec A) C60 N6 (Spec A) C70 N6 (Spec A) C80 N6 (Spec A) C100 N6 (Spec A)

English Original Instructions

8-2017 A051X877 (Issue 6)

Page 2

Page 3

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 Moving Parts Can Cause Severe Personal Injury or Death ................................................... 4

1.5 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 5

1.6 Fuel and Fumes Are Flammable ............................................................................................ 5

1.7 Batteries Can Explode ............................................................................................................ 6

1.8 Exhaust Gases Are Deadly..................................................................................................... 7

1.9 The Hazards of Carbon Monoxide.......................................................................................... 9

1.10 Earth Ground Connection ..................................................................................................... 9

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

2.1 Safety .................................................................................................................................... 11

2.2 About This Manual................................................................................................................ 11

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

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

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

2.6 After Sales Services.............................................................................................................. 19

2.7 General Operating Conditions .............................................................................................. 20

2.8 Generator Set Nameplate .................................................................................................... 21

2.9 Manufacturing Facilities ........................................................................................................ 23

3. CONTROL SYSTEM .................................................................................................................... 25

3.1 Control System Description .................................................................................................. 25

3.2 Display Text or Symbolic Version ......................................................................................... 29

3.3 Exercise Settings ................................................................................................................. 30

3.4 Brightness and Contrast ....................................................................................................... 38

3.5 History and About Menu ....................................................................................................... 40

3.6 Fault Log ............................................................................................................................... 42

3.7 Selecting Operating Modes................................................................................................... 44

3.8 Operating Modes .................................................................................................................. 49

4. OPERATION - POWERCOMMAND 1.1 ...................................................................................... 51

4.1 Introduction ........................................................................................................................... 51

4.2 General Operating Conditions .............................................................................................. 51

4.3 Generator Set Operation....................................................................................................... 51

5. MAINTENANCE ........................................................................................................................... 63

5.1 Maintenance Safety .............................................................................................................. 63

5.2 Periodic Maintenance ........................................................................................................... 66

5.3 Exercising the Generator Set ............................................................................................... 71

5.4 Engine Oil ............................................................................................................................. 71

Page 4

Table of Contents 8-2017

5.5 Air Intake System.................................................................................................................. 77

5.6 Batteries ................................................................................................................................ 79

5.7 Spark Plugs .......................................................................................................................... 83

6. TROUBLESHOOTING ................................................................................................................. 85

6.1 Avoiding Generator Set Shutdowns ..................................................................................... 85

6.2 Fault Code Introduction......................................................................................................... 85

6.3 Engine Is Difficult to Start or Does Not Start ........................................................................ 85

6.4 Code 143 - Engine Oil Pressure Low (Warning) .................................................................. 86

6.5 Codes 146 and 151 - Engine Coolant Temperature High (Warning or Shutdown) .............. 86

6.6 Code 155 - Intake Manifold Temperature High (Shutdown) ................................................. 87

6.7 Code 197 - Coolant Level Low (Warning) ............................................................................ 87

6.8 Code 415 - Engine Oil Pressure Low (Shutdown)................................................................ 88

6.9 Code 441 - Battery Voltage Low (Warning).......................................................................... 88

6.10 Code 488 - Intake Manifold Temperature High (Warning).................................................. 89

6.11 Code 1438 - Fail to Crank (Shutdown) ............................................................................... 90

6.12 Code 1472 - High AC Current (Shutdown) ......................................................................... 90

6.13 Code 5134 - Unknown Shutdown at Idle ............................................................................ 90

Page 5

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 Inc. with specific generator sets. If this manual has been supplied in isolation, please contact your authorized dealer.

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

CAUTION

NOTICE

Page 6

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

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.

Page 7

1. IMPORTANT SAFETY INSTRUCTIONS8-2017

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.

Page 8

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

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.

1.4 Moving Parts Can Cause Severe Personal Injury or Death

• Keep hands, clothing, and jewelry away from moving parts.

Page 9

1. IMPORTANT SAFETY INSTRUCTIONS8-2017

• Before starting work on the generator set, disconnect the battery charger from its AC source, then disconnect the starting batteries using an insulated wrench, negative (–) cable first. This will prevent accidental starting.

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

• 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.

1.5 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death

• Only qualified service personnel certified and authorized to work on power circuits should work on exposed energized power circuits.

• All relevant service material must be available for any electrical work performed by certified service personnel.

• Exposure to energized power circuits with potentials of 50 VAC or 75 VDC or higher poses a significant risk of 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 safety requirements.

1.6 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.

• 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.

Page 10

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

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.

Spillage

Any spillage that occurs during fueling, oil top-off, or oil change must be cleaned up before starting the generator set.

Fluid Containment

NOTICE

Where spillage containment is not part of a Cummins supply, it is the responsibility of the installer to provide the necessary containment to prevent contamination of the environment, especially water courses and sources.

If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals. Any liquid present should be drained out and disposed of in line with local health and safety regulations. Failure to perform this action may result in spillage of liquids which could contaminate the surrounding area.

Any other fluid containment area must also be checked and emptied, as described above.

1.7 Batteries Can Explode

Batteries can explode, causing severe skin and eye burns and can release toxic electrolytes.

Combustible Gases Batteries can explode, causing severe skin and eye burns, and can release

toxic electrolytes. Do not dispose of the battery in a fire, because it is capable of exploding. Do

not open or mutilate the battery. Do not charge frozen batteries.

WARNING

Page 11

1. IMPORTANT SAFETY INSTRUCTIONS8-2017

WARNING

Electric Shock Hazard Batteries present the risk of high short circuit current. When servicing the generator set:

• Remove watches, rings, or other metal objects.

• Use tools with insulated handles.

NOTICE

Servicing of batteries must be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

• Wear safety glasses.

• Do not smoke.

• Do not charge frozen batteries.

• To prevent arcing when disconnecting the battery:

1. Press the Off switch from the display and then press the E-Stop button.

2. Disconnect AC power from any battery chargers.

3. Remove the negative (-) battery cable to prevent starting.

• To prevent arcing when reconnecting the battery:

1. Reconnect the positive (+) cable.

2. Reconnect the negative (-) cable.

3. Reconnect the battery charger to AC power supply.

• When replacing the generator set battery, always replace it with a battery as specified in this manual.

1.8 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.

Page 12

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

Exhaust Precautions

WARNING

Hot Exhaust Gases Contact with hot exhaust gases can cause severe burns. Wear personal protective equipment when working on equipment.

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is

minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

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.

Page 13

1. IMPORTANT SAFETY INSTRUCTIONS8-2017

1.9 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.

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.

1.10 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.

Page 14

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

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.

Page 15

2 Introduction

2.1 Safety

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

2.2 About This Manual

The purpose of this manual is to provide the users with sound, general information. It is for guidance and assistance with recommendations for correct and safe procedures. Cummins Inc. cannot accept any liability whatsoever for problems arising as a result of following recommendations in this manual.

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

Users are respectfully advised that, in the interests of good practice and safety, it is their responsibility to employ competent people to carry out any installation work. Consult your authorized dealer for further installation information. It is essential that the utmost care is taken with the application, installation, and operation of any generator set due to their potentially hazardous nature. Careful reference should also be made to other Cummins Inc. literature. You must operate and maintain your generator set properly if you are to expect safe and reliable operation.

For further assistance, contact your authorized Cummins dealer.

Page 16

2. Introduction 8-2017

NOTICE

This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions:

• This device may not cause harmful interferences.

• This device must accept any interference received, including interference that may cause undesired operation.

2.3 Schedule of Abbreviations

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

AmpSentry, INSITE, and InPower are trademarks of Cummins Inc. PowerCommand is a registered trademark of Cummins Inc.

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 MFM Multifunction Monitor

ASTM American Society for

Testing and Materials (ASTM International)

ATS Automatic Transfer Switch MLD Masterless Load Demand

AVR Automatic Voltage

Regulator

AWG American Wire Gauge NC Not Connected

CAN Controlled Area Network NFPA National Fire Protection

CB Circuit Breaker NO Normally Open

CE Conformité Européenne NWF Network Failure

LTS Long Term Storage

LVRT Low Voltage Ride Through

Mil Std Military Standard

NC Normally Closed

Agency

CFM Cubic Feet per Minute OEM Original Equipment

Manufacturer

CGT Cummins Generator

Technologies

OOR Out of Range

Page 17

2. Introduction8-2017

ABBR. DESCRIPTION ABBR. DESCRIPTION

CMM Cubic Meters per Minute OORH /

Out of Range High

ORH

CT Current Transformer OORL /

Out of Range Low

ORL

D-AVR Digital Automatic Voltage

PB Push Button

Regulator

DC Direct Current PCC PowerCommand®Control

DEF Diesel Exhaust Fluid PGI Power Generation

Interface

DPF Diesel Particulate Filter PGN Parameter Group Number

ECM Engine Control Module PI Proportional/Integral

ECS Engine Control System PID Proportional / Integral /

Derivative

EMI Electromagnetic

interference

PLC Programmable Logic

Controller

EN European Standard PMG Permanent Magnet

Generator

EPS Engine Protection System PPE Personal Protective

Equipment

E-Stop Emergency Stop PT Potential Transformer

FAE Full Authority Electronic PTC Power Transfer Control

FMI Failure Mode Identifier PWM Pulse-width Modulation

FRT Fault Ride Through RFI Radio Frequency

Interference

FSO Fuel Shutoff RH Relative Humidity

Genset Generator Set RMS Root Mean Square

GCP Generator Control Panel RTU Remote Terminal Unit

GND Ground SAE Society of Automotive

Engineers

LCT Low Coolant Temperature SCR Selective Catalytic

Reduction

HMI Human-machine Interface SPN Suspect Parameter

Number

IC Integrated Circuit SWL Safe Working Load

ISO International Organization

for Standardization

SW_B+ Switched B+

Page 18

2. Introduction 8-2017

ABBR. DESCRIPTION ABBR. DESCRIPTION

LBNG Lean-burn Natural Gas UL Underwriters Laboratories

LCD Liquid Crystal Display UPS Uninterruptible Power

Supply

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 to familiarize themselves with the warnings and operating procedures.

The literature provided with the generator set is as follows:

• Operator Manual (A051X877)

• Installation Manual (A051X873)

NOTICE

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:

• Health and Safety Manual (0908-0110)

• Warranty Statement (A028U870)

• C45 N6, C50 N6 and C60 N6 models only: Emissions Component Defect Warranty Statement (A028X278)

• C70 N6, C80 N6 and C100 N6 models only: Emissions Component Defect Warranty Statement (A028X279)

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

• Service Manual (A051X880)

• Parts Manual (A051X891)

• EControls, Inc., Global Control Platform (GCP) Software Service Manual (A035C596)

• EControls, Inc., 4G Software Service Manual (A052G032)

• EControls, Inc., GCP Engine Display Interface Software (EDIS) Training Manual (A035C608)

• EControls, Inc., 4G Software Operator Manual (A052G024)

• Engine Operation & Maintenance Manual for QSJ5.9G (4388606)

• RA Series Transfer Switch Owner Manual (A046S594) - if applicable

Page 19

• PowerCommand® 1302 Controller Owner's Manual (900-0661)

• Service Tool Manual (A043D529)

• Standard Repair Times - HL Family (A053K365)

• T-030: Liquid Cooled Generator Set Application Manual (A040S369) - for application information

2.5 Model Specifications

Damage caused by failure to follow the manufacturer's recommendation will not be covered by the warranty. Please contact your authorized distributor.

TABLE 1. 5.9L MODEL VARIATIONS

Models Description

2. Introduction8-2017

NOTICE

C45 N6, C50 N6, C60 N6, C70 N6, C80 N6, C100 N6 60 Hz, 1800 RPM

TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS)

Temperature Description

Battery

Type

Group

Above 4 °C (40 °F) Battery charger Standard 34

-17 to 4 °C (0 to 40 °F)

Battery charger, coolant heater (1000W), CCV heater

Standard 34

Battery charger, coolant heater (1500W),

Below -17 °C (0 °F)

CCV heaters are provided as part of the cold and extreme cold coolant heater packages.

The cold weather starter is provided as part of the extreme cold coolant heater package.

oil heater, battery heater, CCV heater1, cold weather starter

NOTICE

Larger 4D

For NFPA 110 applications, a coolant heater is required. A factory option is available.

Page 20

2. Introduction 8-2017

TABLE 3. FUEL SPECIFICATIONS 60 HZ, 1800 RPM

Type Unit C45 N6 C50 N6 C60 N6 C70 N6 C80 N6 C100 N6

Liquid Propane

scfh 289.6 321.6 370.2 384.2 420.8 518.7

BTU/hr 651,600 723,600 832,950 864,450 946,800 1,167,075

Full Load

Natural Gas

scfh 711.2 806.3 933.8 988.4 1,083.5 1,317.7

BTU/hr 721,868 818,395 947,807 1,003,226 1,099,753 1,337,466

Full Load

Fuel

6-13 inches of water column (1.5 - 3.2 kPa) under any condition

Pressure

TABLE 4. ENGINE SPECIFICATIONS (ALL MODELS)

Type Specification

Engine

6 cylinder-in-line, single-cam, liquid-cooled, 4-stroke, spark ignited

Bore 102 mm 94.02 in)

Stroke 120 mm (4.72 in)

Displacement 5.88 L (359 in3)

Compression Ratio (Natural Gas & LPG)

8.5:1

Firing Order 1-5-3-6-2-4

Spark Plug Gap 45, 50, 60 kW) 0.508 mm (0.020 in)

Spark Plug Gap (70, 80, 100 kW)

0.40 mm (016 in)

Spark Plug Torque 38 Nm (8 ft-lb)

Crankshaft Rotation (Viewed from the Front of the Engine)

Engine Weight (Dry, Long Block Only)

Clockwise

413 kg (911 lb)

Valve Clearance (Intake) 0.305 mm (0.012 in)

Valve Clearance (Exhaust) 0.610 mm (0.024 in)

• 50/50 coolant solution (50% pure water and 50% anti-

Coolant

freeze)

• 16 L (4.23 gal) capacity

Oil Capacity 15 L (4 gal)

Page 21

Oil Standards

2. Introduction8-2017

Type Specification

• Must adhere to Cummins®Engineering Standard (CES) 20085

• Use of improper oils can result in engine damage. Use only the required oils:

◦ 5W-40 (all ambient temperatures)

◦ 15W-40 (above 4 °C [40 °F] ambient temperature)

(use of GEO 15W-40 oil in ambient temperatures below 4 °C (40 °F] could result in engine turbocharger damage)

• A sulfated ash limit of 0.6% mass has been placed on all engine lubricating oils recommended for use in Cummins® B, natural gas engines. Higher ash oils can cause valve and/or piston damage, cause spark plug fouling, and lead to excessive oil consumption and degradation of the catalyst.

TABLE 5. LUBRICATING OIL SYSTEM SPECIFICATIONS

Type Specification

Lubricating Oil Pressure at Idle (Minimum) 104 kPa (15 psi)

Lubricating Oil Pressure at Rated Speed (Minimum)

Filter Bypass Valve-Opening Pressure 311 kPa (45 psi)

Pressure Regulator Valve-Opening Pressure 449 kPa (65 psi)

Lubricating Oil Capacity (Standard Sump):

--High 14.2 L (15 qt)

--Low 12.4 L (13 qt)

--Total System 15.1 L (16 qt)

TABLE 6. GENERATOR SET SIZE SPECIFICATIONS

Enclosure

Type

Open/Weather

2489 x 1016 x 1473 mm (98 x 40 x 58 in); does not include exhaust

Size (L x W x H)

discharge elbow

Sound Level 1 3023 x 1016 x 1473 mm (119 x 40 x 58 in)

Sound Level 2 3454 x 1016 x 1473 mm (136 x 40 x 58 in)

Page 22

2. Introduction 8-2017

TABLE 7. GENERATOR SET WET WEIGHT (POUNDS) (60 HZ, 1800 RPM)

Configuration C45 N6 C50 N6 C60 N6 C70 N6 C80 N6 C100 N6

Open 2180 2180 2431 2449 2587 2719

Weather 2359 2359 2610 2628 2766 2898

Sound Level 1 2455 2455 2706 2724 2862 2994

Sound Level 2 2485 2485 2736 2754 2892 3024

NOTICE

Weights are approximate and can be affected by selected options. Refer to outline drawings for specific weight information.

TABLE 8. ALTERNATOR SPECIFICATIONS 60 HZ, 1800 RPM

Type C45 N6 C50 N6 C60 N6 C70 N6 C80 N6 C100 N6

Generator Brushless, 4-pole rotating field, single bearing

Power (kVA) 1 Phase 45 50 60 70 80 100

Power (kVA) 3 Phase 56.3 62.5 75 87.5 100 125

120/240, 1 Ph

227/480, 3 Ph

347/600, 3 Ph

Rated Voltages (V)

120/240, 3 Ph

120/208, 3 Ph

127/220, 3 Ph

F1PO (Reconnectable, Full Single Phase Output)

NOTICE

Maximum I2= 8%. Generator set load unbalance must not exceed 25% between any phases.

Page 23

TABLE 9. GENERATOR SET DERATING GUIDELINES

Engine Power Available Up To... Derate At…

Model Phase

Elevation

C45 N6 Both 675 m (2200 ft) 40 °C (104 °F)

C50 N6 Both 150 m (490 ft) 25 °C (77 °F)

C60 N6 Both 1000 m (3280 ft)

Ambient

Temperature

2. Introduction8-2017

Elevation Temperature

C70 N6

C80 N6

C100 N6

1 2575 m (8450 ft)

3 3048 m (10000 ft)

1 1825 m (5985 ft)

3 2500 m (8200 ft)

1 700 m (1560 ft) 25 °C (77 °F)

3 1000 m (3280 ft) 40 °C (104 °F)

TABLE 10. CONTROL SPECIFICATIONS (ALL MODELS)

Control Purpose

PC 1.1 Generator Set

Enovations I28 EPR Engine (45, 50, 60 kW Generator Sets)

Enovations 4G LDI Engine (70, 80, 100 kW Generator Sets)

TABLE 11. DC SYSTEM SPECIFICATIONS (ALL MODELS)

Type Specification

40 °C (104 °F)

per 300 m (985 ft)

per 10 °C (18

°F)

Nominal Battery Voltage 12 VDC

Battery Group

Battery Type Maintenance-free

Minimum Cold Crank Amps

34 standard, 4D high capacity (requires large battery tray)

850 standard, 1080 high capacity (requires large battery tray)

2.6 After Sales Services

Cummins offers a full range of maintenance and warranty services.

Page 24

2. Introduction 8-2017

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 Warranty Statement listed in the Related Literature section.

Extended warranty coverage is also available. 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.

For further warranty details, contact your authorized dealer.

NOTICE

Damage caused by failure to follow the manufacturer's recommendations will not be covered by the warranty. Please contact your authorized dealer.

Warranty Limitations

For details of the warranty limitations for your generator set, refer to the warranty statement applicable to the generator set.

How to Obtain Service

For parts, service, and product information, contact the nearest authorized Cummins Inc. dealer. To easily locate the nearest certified distributor/dealer for Cummins generator sets in your area, or for more information, contact us at 1-800CUMMINSTM(1-800-286-6467) or visit http://www.cummins.com/support.

2.7 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.

Page 25

2. Introduction8-2017

• Do not store anything inside of the generator set.

• Keep areas clear in front of the cool air in and hot air out (free of obstructions, debris, plants, etc.).

NOTICE

All maintenance procedures must be performed or supervised by authorized and trained service personnel only.

No. Description No. Description

1 Cool Air In 3 Hot Air Out (Weather Enclosure)

2 Hot Air Out (Sound Level Enclosure)

FIGURE 1. EXAMPLE OF GENERATOR SET LOCATION

2.8 Generator Set Nameplate

WARNING

Electrical Generating Equipment Improper service or replacement of parts can lead to severe personal injury

or death and to damage to equipment and property. Make sure service personnel are qualified to perform electrical and

mechanical service.

Page 26

2. Introduction 8-2017

NOTICE

Unauthorized modifications or replacement of fuel, exhaust, air intake or speed control system components that affect engine emissions are prohibited by law in the State of California.

Model, Spec, and Serial Numbers: Be ready to provide the model, spec, and

serial numbers on the generator set nameplate when contacting Cummins Inc. for information, parts, and service. The nameplate is located on the inside of the control access door on enclosed products or on the side of the radiator for open products.

Record these numbers so that they are easy to find when needed. Each character in these numbers is significant for obtaining the right parts listed in the Parts Catalog. Genuine Cummins Inc. replacement parts are recommended for best results.

My Generator Set Information

Model

Spec

Serial Number

Page 27

2.9 Manufacturing Facilities

Facility Address Phone Numbers

U.S. and CANADA

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

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

2. Introduction8-2017

EMEA, CIS Cummins Inc.

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

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

ASIA PACIFIC

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

BRAZIL Rua Jati, 310, Cumbica

Guarulhos, SP 07180-900 Brazil

Phone +44 1843 255000 Fax +44 1843 255902

Phone +65 6417 2388 Fax +65 6417 2399

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

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 86 10 59023001 Fax +86 10 5902 3199

Phone +91 021 66305514

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

Page 28

2. Introduction 8-2017

Facility Address Phone Numbers

MEXICO Eje 122 No. 200 Zona Industrial

San Luis Potosi, S.L.P. 78395 Mexico

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

Page 29

3 Control System

3.1 Control System Description

The control system is used to start and stop the generator set, and provides full generator set monitoring capability and protection in a stand-alone situation (nonparalleling) from the display screen. It monitors the engine for temperature, as well as oil pressure and speed. It also provides voltage and current metering. In the event of a fault, the unit indicates the fault type and, on critical faults, automatically shuts down the generator set.

All indicators, control buttons, and the display screen are on the face of the operator panel, as illustrated in the figure below.

There are three fault level signals generated by the control system:

• Event: Signals that a temporary condition exists.

• Warning: Signals an imminent or non-critical fault for the engine. The control provides an indication only for this condition.

• Shutdown: Signals a potentially critical fault for the engine. The control immediately takes the engine off-load and automatically shuts it down.

The standard control system operates on 12 VDC (or 24 VDC if applicable) battery power. History data is stored in non-volatile memory and is not deleted if battery power is lost.

Standard Operator Panel

The operator panel includes indicator lights (LEDs), display buttons used to navigate through the menus, control mode buttons, and an LCD display. The display enables the operator to check the status, adjust the settings, and start and stop the generator set. The standard operator panel (show below) is located on every generator set. An optional in-home operator panel accessory is also available for location inside the home.

Page 30

3. Control System 8-2017

FIGURE 2. STANDARD OPERATOR PANEL (HMI211)

Standard Key Functions (HMI211)

The user interface includes two fixed action buttons and four soft key buttons. The action of the soft key buttons changes to meet the requirements of each screen.

TABLE 12. KEY FUNCTIONS

Key/Symbol Action

Switches to Off mode (fixed action button).

Switches to Auto mode.

Switches to Manual Run mode.

Navigates to the previous menu level (fixed action button).

(Up Arrow) Navigates to the previous screen/menu in a list.

(Down Arrow) Navigates to the next screen/menu in a list.

and Hold the up and down arrows simultaneously for two seconds from any

Info Menu to navigate to the Menu screen.

Save Saves changes and navigates to the associated screen.

Adjust Navigates to the Adjust Menu of a specific menu.

(Right Arrow) Advances the highlighted field to the next editable field.

Page 31

Key/Symbol Action

- Decreases value of the highlighted editable field.

+ Increases value of highlighted editable field.

Standard LED Indicators (HMI211)

The operator panel has six LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below.

TABLE 13. LED INDICATORS

LED Color Action

Not in Auto Red Indicates the generator set is in Manual or Off Mode.

Shutdown Red Indicates a Shutdown Fault has occurred.

Warning Yellow Indicates a Warning Fault has occurred.

3. Control System8-2017

Remote Start

Auto Green Indicates that the generator set is in Auto Mode. The generator starts

Manual Run Green Indicates that the generator set has received a Manual Run

Green Indicates that the generator set has received a Remote Start

Command.

when it receives a Remote Start Command.

Command.

In-Home Operator Panel (Accessory)

The in-home operator panel is an optional display that may be purchased. This panel is intended to serve as a convenience option to the standard operator panel mounted on the generator set.

Page 32

3. Control System 8-2017

FIGURE 3. IN-HOME OPERATOR PANEL

Key Functions (In-Home Operator Panel)

The user interface includes two fixed action buttons and four soft key buttons. The action of the soft key buttons changes to meet the requirements of each screen.

TABLE 14. KEY FUNCTIONS

Key/Symbol Action

Stop Switches to Off mode. This key works from any screen (fixed action

button).

(Up Arrow) Navigates to the previous screen/menu in a list.

(Down Arrow) Navigates to the next screen/menu in a list.

and Hold the up and down arrows simultaneously for two seconds from any Info

Menu to navigate to the Service Menu.

Back Navigates to the previous screen/menu in a list (fixed action button). In

Adjust screens, settings are not saved.

Save Saves changes and navigates to the associated screen.

Adjust Navigates to the Adjust Menu of a specific menu.

(Right Arrow) Advances the highlighted field to the next editable field.

- Decreases value of the highlighted editable field.

+ Increases value of highlighted editable field.

Page 33

3. Control System8-2017

LED Indicators (In-Home Operator Panel)

The operator panel has five LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below.

TABLE 15. LED INDICATORS

LED Color Action

Shutdown Red Indicates a Shutdown Fault has occurred.

Warning Yellow Indicates a Warning Fault has occurred.

Auto Start Green Indicates that the generator set has received a Remote Start

Command.

Auto Green Indicates that the generator set is in Auto Mode. The

generator starts when it receives a Remote Start Command.

Manual Run Green Indicates that the generator set has received a Manual Run

Command.

3.2 Display Text or Symbolic Version

The operator panel graphical display can be set to show text (English only) or symbols for fault messages, operator menus, and the Mode Change Menu. Descriptions of commonly used symbols are included in the following table. Combinations of symbols are used to display some fault conditions.

When shipped from the factory, the display is set to display symbols. Qualified service personnel are required to change the default setting.

TABLE 16. SYMBOLS

Symbol Text

Generator Warning Fault

Generator Shutdown Fault

Coolant Temperature

Oil Pressure

Voltage Alternating Current (VAC)

Voltage Direct Current (VDC)

AC Current

Hz Frequency

Page 34

3. Control System 8-2017

Symbol Text

Battery

Out of Range

High or Pre-High

Low or Pre-Low

Annunciator

Over Speed

Crank Fail

Emergency Stop

3.3 Exercise Settings

When battery power is lost, these settings must be reset.

Not applicable without an RA series transfer switch.

To access the Clock/Exerciser Menu:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Navigate through the screens to find and select Clock/Excr in the Service Menu.

The following screens represent the standard operator panel (that is, HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels.

NOTICE

Page 35

3. Control System8-2017

FIGURE 4. CLOCK/EXERCISER MENU NAVIGATION

Page 36

3. Control System 8-2017

Updating Exercise Frequency (3-Phase ATS)

NOTICE

Not applicable without an RA series transfer switch.

To update the exercise frequency and dates on the Clock/Exerciser Menu:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu.

3. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen.

4. Select Adjust.

5. Press the down key on the Daylight Saving Adjust Start screen.

6. Select Adjust.

7. Press Exercise Schdr on the Daylight Saving Adjust End screen.

8. Press Adjust.

When updating these settings, the functions of the keys are as follows:

• The horizontal right arrow key is used to select successive blocks for editing settings on the screen.

• Use the + or - keys to edit the following settings:

◦ Schdr Enable: Enable or Disable

◦ Exercise Schedule: Semi-Annual (every six months), Quarterly, Monthly,

Bi-Weekly (every two weeks) , or Weekly

◦ Exercise Schedule: Day, Hours, Minutes, AM/PM

• Press Save to save any changes. After saving, the Save button changes to the Adjust button.

Page 37

FIGURE 5. EXERCISE FREQUENCY NAVIGATION

3. Control System8-2017

Updating Exercise Duration (3-Phase ATS)

NOTICE

Not applicable without an RA series transfer switch.

To update the exercise duration on the Clock/Exerciser Menu:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu.

3. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen.

4. Select Adjust.

5. Press the down key on the Daylight Saving Adjust Start screen.

6. Select Adjust.

7. Press Exercise Schdr on the Daylight Saving Adjust End screen.

8. Press the down key on the Exercise Schdr Menu.

9. Press Adjust.

When updating these settings, the functions of the keys are as follows:

• The horizontal right arrow key is used to select the duration block for editing exercise duration.

• Use the + or - keys to edit the exercise duration minutes.

Page 38

3. Control System 8-2017

• Press Save to save any changes. After saving, the Save button changes to the Adjust button.

FIGURE 6. EXERCISE DURATION NAVIGATION

Time Setup (3-Phase ATS)

NOTICE

When battery power is lost, these settings must be reset.

NOTICE

Not applicable without an RA series transfer switch.

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

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu.

3. Select Adjust.

When updating these settings, the functions of the keys are as follows:

• The horizontal right arrow key is used to select successive blocks for editing settings on the screen.

• Select the left arrow to return to the previous screen.

• Adjust values by using the + or - keys on the Adjust Menu of the Time Setup screen.

• Press Save to save any changes. After saving, the Save button changes to the Adjust button.

Page 39

FIGURE 7. TIME SETUP SCREEN

Updating Daylight Saving Adjust Screens

3. Control System8-2017

Update Values on the Daylight Saving Adjust Screen

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Navigate to the Genset Service Menu.

3. Select Clock Exerciser to access the Time Setup screen.

4. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen.

5. Select Adjust. When updating these settings, the functions of the keys are as follows:

TABLE 17. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST SCREEN

Key/Button Function

Horizontal right arrow key Select successive blocks for editing settings on the screen

Left arrow key Return to the previous screen

+ or - keys Adjust values on the Adjust screen of the Daylight Saving Adjust

screen

Save button Save any changes; after saving, the Save button changes to the

Adjust button

Page 40

3. Control System 8-2017

FIGURE 8. "DAYLIGHT SAVING ADJUST SAVING TIME" SCREEN NAVIGATION

Access and Update the Daylight Saving Adjust Start Screen

1. Press the down arrow key on the Daylight Saving Adjust screen.

2. Press Adjust. When updating these settings, the functions of the keys are as follows:

TABLE 18. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST START SCREEN

Key/Button Function

Horizontal right arrow key Select successive blocks for editing settings on the screen

+ or - keys Adjust Month, Week, Day or Hour

Save button Save any changes; after saving, the Save button changes to the

Adjust button

Page 41

FIGURE 9. DAYLIGHT SAVING ADJUST START SCREEN

3. Control System8-2017

Update the Daylight Saving Adjust End Screen

1. Press the down key on the Daylight Saving Adjust Start screen.

2. Press Adjust. When updating these settings, the functions of the keys are as follows:

TABLE 19. KEY FUNCTIONS ON THE DAYLIGHT SAVING ADJUST END SCREEN

Key/Button Function

Horizontal right arrow key Select successive blocks for editing settings on the screen

+ or - keys Adjust Month, Week, Day or Hour

Save button Save any changes; after saving, the Save button changes to the

Adjust button

Page 42

3. Control System 8-2017

FIGURE 10. DAYLIGHT SAVING ADJUST END SCREEN

3.4 Brightness and Contrast

The Screen Adjust screen allows the contrast, brightness, and units to be set. To access the Screen Adjust screen:

1. From any Information screen, hold down the up and down arrows simultaneously for two seconds to gain access to the Service Menu screen.

2. Select Screen Adjust.

To adjust the contrast, brightness, or units from the Screen Adjust screen:

1. From the Screen Adjust screen, select Adjust to access the screen variables.

2. Press the right arrow to move between the variables.

3. Adjust settings, and press Save to save any changes.

When updating these settings, the functions of the keys are as follows:

• The horizontal right arrow key is used to select successive blocks for editing settings on the screen.

• Select the left arrow to return to the previous screen.

• Adjust values by using the + or - keys on the Adjust screen of the Display Setup screen.

• Press Save to save any changes. After saving, the Save button changes to the Adjust button.

Page 43

3. Control System8-2017

NOTICE

The following screens represent the standard operator panel (HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels.

FIGURE 11. BRIGHTNESS AND CONTRAST SCREEN NAVIGATION

Page 44

3. Control System 8-2017

NOTICE

Adjusting the brightness on the operator panel adjusts the brightness of both the LCD backlight and the LEDs on the display. The contrast should never be 0 or 100% on any of the screens. The default value for Brightness is 50%.

3.5 History and About Menu

To access the History/About screen:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Select History/About.

3. Advance through the screens to view information about the generator set, control, and display.

NOTICE

Page 45

3. Control System8-2017

FIGURE 12. HISTORY/ABOUT MENU

Page 46

3. Control System 8-2017

3.6 Fault Log

To check the fault log:

1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears.

2. Select Fault History.

NOTICE

The active faults are displayed first. If there are no active faults, this screen is skipped. Following the Active Faults screen are the Fault History screens. These screens display the faults in chronological order from newest to oldest.

NOTICE

Page 47

3. Control System8-2017

FIGURE 13. FAULT LOG SCREEN

Page 48

3. Control System 8-2017

3.7 Selecting Operating Modes

Selecting Manual Run Mode

WARNING

Electrical Generating Equipment When changing modes, the generator set can start or stop without warning

(for example, Auto Mode may have been selected with no mains (utility) power available).

Make sure there is no danger to personnel or equipment, if the generator set starts or stops when changing modes.

1. Before proceeding to change the mode, make sure that it is safe to do so.

2. Press the Manual Run button on any of the Operator menus or the "Establishing/Re-establishing communication with control" menus.

3. If the Mode Change Access Code menu is enabled, the Mode Change Access Code is displayed. Enter the Mode Change Access Code.

4. A menu with alternating arrows is displayed above a second symbol.

5. Press the second Manual Run button, and the generator set will now begin the Manual start sequence. The Operator menu that was displayed before

Manual Run mode was selected is re-displayed, but with the symbol blacked out.

NOTICE

To disable Manual Run mode, press the Off button.

NOTICE

Auto mode can also be selected while in Manual Run mode. Switching to Auto mode may result in the generator set shutting down.

Page 49

3. Control System8-2017

No. Description No. Description

1 Menu Displayed Only When the Mode

3 Manual Run Mode Selected Change Access Code Feature Is Enabled

2 Alternating Arrows Displayed

FIGURE 14. SELECTING MANUAL RUN MODE

Page 50

3. Control System 8-2017

Selecting Auto Mode

WARNING

Electrical Generating Equipment When changing modes, the generator set can start or stop without warning

(for example, Auto Mode may have been selected with no mains (utility) power available).

Make sure there is no danger to personnel or equipment, if the generator set starts or stops when changing modes.

To switch to Auto mode (see Figure 15 on page 47),

1. Ensure that it is safe to do so before proceeding to change the mode.

2. Press the Auto button on any of the Operator menus, or the ‘Establishing/Re-establishing communication with control’ menus.

3. If the mode change access code feature is enabled, the Mode Change Access Code menu is displayed. Enter the Mode Change Access Code.

4. A menu with alternating arrows will then be displayed above a second Auto symbol.

5. Press this second Auto button. The Operator menu that was displayed before Auto mode was selected is re-displayed, but with the Auto symbols

blacked out and Manual Run symbols visible.

To disable Auto mode, press the Off button.

The generator set is now ready to receive a remote start signal that will initiate the Auto run mode.

WARNING

Should a remote start signal be received, the generator set starts automatically. Make sure there is no danger to personnel or equipment should the generator set start without warning.

NOTICE

Manual Run mode can also be selected FROM Auto mode. Switching to Manual Run mode results in the generator set starting up.

Page 51

3. Control System8-2017

No. Description No. Description

1 This Menu Is Displayed Only if the

3 Auto Mode Selected Mode Change Access Code Feature Is Enabled

2 Alternating Arrows Are Displayed

FIGURE 15. SELECTING AUTO MODE

Page 52

3. Control System 8-2017

Selecting Off Mode

WARNING

Electrical Generating Equipment When changing modes, the generator set can start or stop without warning

(for example, Auto Mode may have been selected with no mains (utility) power available).

Make sure there is no danger to personnel or equipment, if the generator set starts or stops when changing modes.

To switch to Off mode (see the figure below),

1. Make sure that it is safe to do so before proceeding to stop the set.

2. Press the Off button on any of the Operator menus or the "Establishing/Reestablishing communication with control" menus.

3. If the Mode Change Access Code is enabled, the Mode Change Access Code will be displayed. Enter the Mode Change Access Code.

4. On entering the last correct digit, the basic screen will re-appear, and the set will stop without a Time Delay to Stop.

NOTICE

Make sure that there is no danger to personnel or equipment if the generator set is stopped.

Page 53

3. Control System8-2017

No. Description No. Description

1 Off Button 2 This Mode Is Displayed Only if the

Mode Change Access Code Feature Is Enabled

FIGURE 16. SELECTING OFF MODE

3.8 Operating Modes

The generator set's PowerCommand®control has Manual Run, Off, and Auto operating modes that are available from the operator panel.

Page 54

3. Control System 8-2017

Off Mode

When in Off mode, the control does not allow the generator set to start. If the generator set is already running and the control is set to Off, it initiates a normal shutdown sequence.

Manual Run Mode

When in Manual Run mode, the generator set starts and continues to run until the control is put into the Off mode. While in Manual Run mode, the remote start signal is ignored.

Auto Mode

When in Auto mode, the control allows the generator set to be started with a remote start signal only.

When in Auto mode, the generator set can start at any time. When a remote start signal is received, the genset starts after a time delay preheat (if programmed) and time delay start (if programmed) is completed.

If the generator set is running in Auto mode and the Off button is pressed, the control immediately stops the genset and the control transitions to the Off mode.

When all remote start signals are removed, the control performs a normal shutdown sequence which may include a time delay stop.

Page 55

4 Operation - PowerCommand 1.1

4.1 Introduction

This section describes the operation of the generator set. The text should be read in conjunction with the Control System section of this manual.

All indicators, control switches/buttons, and graphical display are located on the face of the Operator Panel.

4.2 General Operating Conditions

The area surrounding the generator set is critical for safety and its performance. Follow the guidelines below.

• Do not stack anything on top of the generator set.

• 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 an engine 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 engine will result in longer life, better performance, and more economical operation.

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 dealer for further information.

Page 56

4. Operation - PowerCommand 1.1 8-2017

NOTICE

Diesel engines only: Cummins Inc. recommends the installation of an air

intake shutoff device or a similar safety device to minimize the risk of overspeeding where an engine will be operated in a combustible environment.

NOTICE

Long periods of idling (more than ten minutes) can damage an engine. Do not idle the engine for excessively long periods.

Sequence of Operation

NOTICE

The following sequences are based on an approximate time duration. 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 an RA series transfer switch.

Power Outage Sequence

The sequence of operation after a power outage (when the generator set is in Auto Mode) is as follows:

1. In normal operation, the utility power is running to the transfer switch and then to the building load, and the generator set is off.

2. The utility power turns off (power outage).

3. One second after the power outage, the transfer switch sends the command to the generator set to start.

4. If the ambient temperature is below 20 °F/-6.7 °C, the generator set will idle at 800 rpm for up to 2 minutes to allow sufficient turbo lubrication.

• The set points are 20 °F/-6.7 °C and below, ramping linearly from 0 sec (20 °F/-6.7 °C) to 2 minutes (-40 ° F/-40 °C) and held constant at 2 minutes if below -40 °F/-40 °C.

FIGURE 17. COLD START IDLE ACTIVE

Page 57

4. Operation - PowerCommand 1.18-2017

NOTICE

The control box area is equipped with an ambient temperature sensor for controlling the idle feature. Do not install any heaters in the control box area as this can influence the sensor and lead to engine damage.

5. After the generator set ramps up to rated speed, the generator set provides voltage to the transfer switch, but the transfer switch does not switch (allowing the voltage to go to the building) until after a delay.

FIGURE 18. TIME REMAINING UNTIL TRANSFER SCREEN

6. Five seconds after starting, the generator set provides a signal to the transfer switch to transfer the building load to the generator set.

FIGURE 19. BUILDING LOAD TRANSFER IN PROCESS

7. The transfer switch switches the generator set power to the building load. The building is now running on generator power.

FIGURE 20. GENERATOR SET POWERING BUILDING LOAD

8. When the utility power is back and providing voltage to the transfer switch, the transfer switch waits for utility power stability.

Page 58

4. Operation - PowerCommand 1.1 8-2017

FIGURE 21. TIME REMAINING UNTIL RE-TRANSFER

9. When the utility power is stable for 5 minutes, the transfer switch switches back to utility power.

FIGURE 22. BUILDING LOAD TRANSFER IN PROCESS

FIGURE 23. UTILITY POWERING BUILDING LOAD

10. The generator set runs for a 5-minute cooldown and shuts off.

FIGURE 24. TIME REMAINING UNTIL STOP

11. Normal operation resumes.

Exercise Sequence

The exercise sequence when the programmed exercise time is realized (the generator set is in Auto Mode) is as follows:

1. The generator set starts and runs.

Page 59

4. Operation - PowerCommand 1.18-2017

2. If the ambient temperature is below 20 ° F (6.7 °C), the generator set will idle at 800 rpm for up to 2 minutes to allow sufficient turbo lubrication.

• Idle time is linear from 2 minutes at -40 °F (4 °C), or below to off at 20 °F (6.7 °C) or above.

FIGURE 25. COLD START IDLE ACTIVE

3. The Exerciser Scheduler On screen displays every 3 seconds and toggles between the existing Information screen that is displayed for 1 second.

FIGURE 26. EXERCISER SCHEDULER SCREEN AND INFORMATION SCREEN

TOGGLE - EXAMPLE

4. The transfer switch is not commanded to switch the building load to the generator set.

NOTICE

The user may navigate to other screens from the Information screens during this duration. No functional keys are active on the Exerciser Scheduler On screen.

5. The generator set stops after programmed exercise run time.

Manually Starting the Generator Set Sequence

If the generator set is manually started with the standard operator panel, HMI211 (the generator set is in Man Mode), the sequence is as follows:

Page 60

4. Operation - PowerCommand 1.1 8-2017

NOTICE

Open the generator set main line circuit breaker to prevent the transfer switch from transferring building load to the generator set. The generator set display will still show the RA series ATS transfer; however, the switch will not transfer if the generator set breaker is open.

1. In normal operation, the utility power is running to the transfer switch and then to the building load, and the generator set is off.

2. Manually start the generator set via the standard control (HMI211) mounted on the generator set.

FIGURE 27. MANUAL START SCREEN, STANDARD OPERATOR PANEL

3. The generator set starts.

4. If the ambient temperature is below 20 ° F (6.7 °C), the generator set will idle at 800 rpm for up to 2 minutes to allow sufficient turbo lubrication after which the generator will ramp up to rated speed.

• Idle time is linear from 2 minutes at -40 F (4 °C), or below to off at 20 °F (6.7 °C) or above.

Page 61

4. Operation - PowerCommand 1.18-2017

FIGURE 28. COLD START IDLE ACTIVE

5. The generator set provides voltage to the transfer switch. (However, the transfer switch does not transfer in manual mode.)

Remote Starting the Generator Set Sequence

If the generator set is remote started with the in-home operator panel accessory, if equipped (the generator set is in Auto Mode), the sequence is as follows:

1. In a normal operation, the utility power is running to the transfer switch and then to the building load, and the generator set is off.

2. The generator set-mounted control (HMI211) is set in Auto Mode.

Page 62

4. Operation - PowerCommand 1.1 8-2017

FIGURE 29. HMI211 SET IN AUTO MODE

3. Manually start the generator set via the in-home operator panel.

Page 63

4. Operation - PowerCommand 1.18-2017

FIGURE 30. MANUAL START SCREEN, IN-HOME OPERATOR PANEL

4. The generator set starts and provides voltage to the transfer switch, but the transfer switch does not switch (allowing the voltage to go to the building) until after a delay.

FIGURE 31. TIME REMAINING UNTIL TRANSFER SCREEN

5. Five seconds after starting, the generator set provides a signal to the transfer switch to transfer the building load to the generator set.

Page 64

4. Operation - PowerCommand 1.1 8-2017

FIGURE 32. BUILDING LOAD TRANSFER IN PROCESS

6. If the ambient temperature is below 20 °F (6.7 °C) , the generator set will idle at 800 rpm for up to 2 minutes to allow sufficient turbo lubrication.

• Idle time is linear from 2 minutes at -40 F (40 °C), or below to off at 20 °F (6.7 °C) or above.

FIGURE 33. COLD START IDLE ACTIVE

7. The transfer switch switches the generator set power to the building load. The building is now running on generator power.

FIGURE 34. GENERATOR SET POWERING BUILDING LOAD

8. When the remote display Stop button is pressed, the transfer switch switches back to utility power after a 5 minute retransfer delay.

FIGURE 35. BUILDING LOAD TRANSFER IN PROCESS

Page 65

4. Operation - PowerCommand 1.18-2017

FIGURE 36. UTILITY POWERING BUILDING LOAD

9. The generator set runs for a 5-minute cooldown and shuts off.

FIGURE 37. TIME REMAINING UNTIL STOP

10. Normal operation resumes.

Page 66

4. Operation - PowerCommand 1.1 8-2017

This page is intentionally blank.

Page 67

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.

Page 68

5. Maintenance 8-2017

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.

Page 69

5. Maintenance8-2017

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."

Page 70

5. Maintenance 8-2017

5.2 Periodic Maintenance

WARNING

Electrical Generating Equipment Accidental or remote starting of the generator set can cause severe personal

injury or death. Before working on the generator set, make sure that the generator set is in

Off mode, disable the battery charger, and remove the negative (– ) battery cable from the battery to prevent starting.

The table(s) that follow show the recommended service intervals for a generator set on standby service. 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

• 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.

Page 71

5. Maintenance8-2017

Periodic Maintenance Schedule

NOTICE

Perform maintenance tasks as specified using daily or hourly periods, whichever is sooner.

TABLE 20. PERIODIC MAINTENANCE SCHEDULE

Maintenance Items

Check air cleaner restriction indicator (where fitted): If the indicator shows red, replace air cleaner element and reset the indicator.

Check air intake system for leaks: Visually inspect for signs of wear or damage. Check audibly when the generator set is running. Replace worn or damaged components.

Check coolant level of radiator: If low, top up to coolant system specifications level, with Cummins recommended coolant mix.

Check cooling fan blades: Visually inspect the blades through the guarding for signs of wear or damage. To replace, contact your authorized distributor.

After Every

24 Hours

of Run

Time

■

After Every

50 Hours

of Run

Time

12 Months or

After 250

Hours

2 Years or

After 500

Hours

Checking drive belt condition and tension: Visually check belt for evidence of wear or slippage. To replace, contact your authorized distributor.

■

Page 72

5. Maintenance 8-2017

Maintenance Items

Check radiator airflow: Visually inspect the radiator through the guarding for blockage, debris or signs of wear or damage. To clean or replace, contact your authorized distributor.

Check fuel lines and hoses: Visually check for leaks, worn or damaged hoses. To replace, contact your authorized distributor.

Check engine oil level: If low, top up to engine specifications level with recommended oil.

Check charge alternator: Check visually and audibly when the generator set is running. To replace, contact your authorized distributor.

After Every

24 Hours

of Run

Time

■

After Every

50 Hours

of Run

Time

12 Months or

After 250

Hours

2 Years or

After 500

Hours

Check all exhaust components and hardware (fittings, clamps, fasteners, etc.): Visually inspect the exhaust system for signs of wear or damage. Check audibly when the generator set is running.

Check generator set enclosure: Visually check enclosure. Make sure no inlets/outlets are restricted, service access doors are operational. To replace damaged parts, contact your authorized distributor.

Check operation of operator panel: Check display (the system will perform a control panel test on initial activation). Replace component if not functioning properly.

■

Page 73

5. Maintenance8-2017

Maintenance Items

Check operation of Emergency

After Every

24 Hours

of Run

Time

After Every

50 Hours

of Run

Time

■

12 Months or

After 250

Hours

Stop Button (where fitted): With the generator set running, press the Emergency Stop button. Check all systems before resetting the fault.

Replace air cleaner. ■

Check coolant lines and radiator hoses for leaks, wear and cracks: Visually check the hoses. Replace worn or damaged components.

Clean radiator core. ■

Check water pump for leaks. Check weep holes for evidence of leaks. Replace if leaking.

2 Years or

After 500

Hours

■

Verify that the coolant heater has power and is running (where fitted). Check for evidence of leaks. Remove any corrosion from fittings.

Check CCV heater (where fitted). Check for evidence of leaks. Remove any corrosion from fittings.

Check alternator heater (where fitted). Check general condition and wiring connections.

Check battery heater (where fitted). Check general condition and wiring connections.

Check engine oil heater (where fitted). Check general condition and wiring connections.

Check battery: Check connections to verify that they are secure.

■

Page 74

5. Maintenance 8-2017

Maintenance Items

Check battery for general condition. Remove any corrosion on terminals with wire brush.

Check electrical connections (battery, starter motor, alternator connections). Check for tight connections, general condition and remove any corrosion.

Replace engine oil and filters. Refer to the Engine Oil section for the procedure.

Check engine ground. Clean as necessary.

Check engine mounts for general condition and for signs of excessive wear.

After Every

24 Hours

of Run

Time

After Every

50 Hours

of Run

Time

■

12 Months or

After 250

Hours

■

2 Years or

After 500

Hours

Check starting motor. ■

Check turbocharger for signs of leakage. Listen for excessive noise when test running the generator set.

Inspect spark plugs. Replace if showing signs of excessive wear, carbon deposits, oil accumulation or damaged.

Replace spark plugs and spark plug wires.

Check charge air cooler for damage and debris.

Check valve lash and adjust if required. See the Valve Clearance Adjustment procedure (service manual only).

Check fan drive idler arm and fan belt tensioner for general condition, as well as for excessive play in both.

■

Page 75

5. Maintenance8-2017

Maintenance Items

After Every

24 Hours

of Run

Time

After Every

50 Hours

of Run

Time

12 Months or

After 250

Hours

2 Years or

After 500

Hours

Replace cooling system coolant. Check coolant sensor for damage and debris.

This interval is based on generator run time: daily in an outage or after every 24 hours of

run time.

To be performed by a qualified Service Technician.

Cleaning schedule may be reduced depending on operating conditions/environment.

After the initial 50 hour interval and every 250 hours thereafter.

5.3 Exercising the Generator Set

NOTICE

Audible engine RPM variation may be heard when there is no load applied. This is normal and does not affect the generator set performance.

■

Exercising the generator set drives off moisture, relubricates the engine, and removes oxides from electrical contacts. The result is better starting, more reliable operation and longer engine life.

The generator set exerciser mode defaults are as follows.

• Day: Tuesday

• Time: 2:00 pm

• Period: Monthly

• Run Time: 5 minutes

Refer to the Exercise Settings section of this manual for more information on setting up the exerciser.

5.4 Engine Oil

Recommended Engine Oil

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

The use of quality engine oils combined with appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability.

Cummins Inc. recommends the use of a high quality SAE 5W-40 GEO (all ambients) or SAE 15W-40 GEO (above 40 °F [4 °C]) engine oil for natural gas engines. In addition, oil needs to conform with CES 20085. Refer to the Model Specifications section for oil specification details.

Page 76

5. Maintenance 8-2017

NOTICE

Use of improper oils can result in engine damage. Use only the recommended oils.

NOTICE

Use of GEO 15W-40 oil in ambient temperatures below 40 °F (4 °C) could result in engine turbocharger damage.

Checking Engine Oil Level

WARNING

Automated Machinery Accidental or remote starting of the generator set can cause severe personal

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

starting battery cables, negative (–) cable first.

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

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.

WARNING

Toxic Hazard Crankcase pressure can blow out hot oil and cause severe burns. Do NOT check oil while the engine is operating.

NOTICE

Check the engine oil level when the engine is not running and is out of Auto mode.

Page 77

5. Maintenance8-2017

NOTICE

Overfilling can cause foaming or aeration of the oil, and operation below the low mark may cause loss of oil pressure. Do not operate the engine with the oil level below the low mark or above the high mark.

No. Description No. Description

1 Fill Cap 3 Oil Filter

2 Dipstick 4 Oil Drain Hose

FIGURE 38. ENGINE OIL COMPONENTS

1. Make sure the generator set is shut down and disabled:

a. Press the Off switch from the display and then press the E-Stop button to

stop the generator set. Allow the generator set to thoroughly cool to the touch.

b. Turn off and disconnect the battery charger from the AC source before

disconnecting the battery cables.

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

contacting the battery terminals to prevent accidental starting.

2. To check the engine oil level:

a. Make sure that the engine has not been running for approximately five

minutes.

b. Clean off the area surrounding the dipstick port to prevent entry of debris

into the oil pan.

c. Pull out the dipstick and wipe it clean.

Page 78

5. Maintenance 8-2017

d. Reinsert and fully seat the dipstick.

e. Remove the dipstick and check the oil level.

NOTICE

The engine oil level indicated on the dipstick should be between the High (15 qt [14.2L]) and Low (13 qt [12.4L]) marks.

f. Reinsert and fully seat the dipstick.

If the engine oil level check shows excessive or insufficient levels of oil (that is, oil level line above the High mark or below the Low mark), oil must be drained or added. Refer to the following sections for instructions and guidelines for draining and adding oil.

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.

Page 79

Draining Oil

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

1. Detach the oil drain hose from the side of the engine.

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

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

• Open the oil drain valve to release oil from the engine into the appropriate container.

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

• When a sufficient amount of oil has been drained from the system:

1. Close the oil drain valve.

2. Wipe the oil drain valve clean.

3. Re-attach the drain hose to the side of the engine.

4. Dispose of the used oil in accordance with local/state regulations.

Changing Engine Oil and Oil Filter

5. Maintenance8-2017

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 (–) 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 engine is not running and is out of Auto mode.

NOTICE

Change the oil more often in hot and dusty environments.

Page 80

5. Maintenance 8-2017

NOTICE

Cummins highly recommends that any service or maintenance work be performed by qualified technicians.

1. Before changing the oil, the generator set should be operated until the water temperature is approximately 60 °C (140 °F).

2. Make sure the generator set is shut down and disabled:

a. Press the generator set's "O" (Off) button to stop the generator set. Allow

the generator set to thoroughly cool to the touch.

b. 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.

3. Drain the oil. Place the end of the drain hose into an appropriate container.

NOTICE

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

4. Remove the oil filter, and clean the filter mounting surface on the engine block. Remove the old gasket if it remains.

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

6. 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.

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

8. Close the oil drain valve.

9. 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.

10. Operate the engine at idle to inspect for leaks at the lubricating oil filter and the drain plug.

11. Confirm that the correct oil level is in the pan:

a. Shut the generator set off and wait 5 minutes.

b. Check the engine oil level.

12. Check and repair any leaks identified.

Page 81

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

5.5 Air Intake System

The direct flow air cleaner consists of a primary filter and a secondary filter within the air cleaner housing. The air cleaner has been designed for a maximum restriction at 25 in water column (6.2 kPa), at which point the filter elements should be changed.

Normal Duty Air Cleaner Element Replacement

Holes, loose-end seals, dented sealing surfaces, corrosion of pipes, and other forms of damage render the air cleaner inoperative and require immediate element replacement or engine damage can occur.

Cummins Inc. does not recommend cleaning paper-type air cleaner elements.

5. Maintenance8-2017

NOTICE

1. Remove the existing air cleaner:

a. Loosen the strap clamp (2).

b. Wipe away any debris accumulated around the air cleaner connection to

the engine. Ensure that no debris is allowed to enter the body of the air cleaner or the connection on the engine.

c. Remove the dirty air cleaner (1).

d. Dispose of the dirty element in accordance with local environmental

agency requirements.

2. Install the replacement air cleaner (1) as follows:

a. Install the air cleaner (1).

b. Tighten strap clamp (2). Torque to 2.5 - 3.3 ft-lb (4.3 - 4.65 Nm).

Page 82

5. Maintenance 8-2017

No. Description No. Description

1 Air Cleaner 2 Strap Clamp

FIGURE 39. EXAMPLE OF NORMAL DUTY AIR CLEANER

Heavy Duty Air Cleaner Element Replacement

CAUTION

Holes, loose-end seals, dented sealing surfaces, corrosion of pipes, and other forms of damage render the air cleaner inoperative and require immediate element replacement or engine damage can occur.

NOTICE

Cummins Inc. does not recommend cleaning paper-type air cleaner elements.

1. To remove the existing air cleaner element:

a. Before disassembly, wipe dirt from the cover and the upper portion of the

air cleaner.

b. Lift the latch (3) and turn the end cover (4) counterclockwise.

c. Pull the end cover (4) away from the housing (1).

d. Remove the air filter element (2) from the housing (1).

e. Dispose of the dirty element in accordance with local environmental

agency requirements.

2. To install the replacement air cleaner element:

a. Ensure that no debris enters the filter element or connection point on the

air cleaner housing.

b. Insert the air filter element (2) into the housing (1).

c. Install the end cover (4) onto the housing (1).

Page 83

5. Maintenance8-2017

d. Turn the end cover (4) clockwise until the latch (3) snaps into place.

No. Description No. Description

1 Housing 3 Latch

2 Air Filter Element 4 End Cover

FIGURE 40. EXAMPLE OF HEAVY DUTY AIR CLEANER

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.

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.

Page 84

5. Maintenance 8-2017

Batteries must never be stacked on top of each other and must be protected from the floor by a wooden pallet or suitably thick cardboard sheet.

Safety Precautions

Servicing of batteries are to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

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.

Page 85

5. Maintenance8-2017

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.

Page 86

5. Maintenance 8-2017

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.

Page 87

Battery Replacement

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

5. Maintenance8-2017

WARNING

NOTICE

Make sure service personnel are qualified to perform electrical and mechanical service.

The generator set has six spark plugs, all accessible from the top of the engine. The spark plugs must be in good condition for proper engine starting and performance. A spark plug that fouls frequently or has heavy soot deposits indicates the need for engine service.

1. Set the generator set control to the Off position before checking the spark plugs.

2. To prevent cross-threading a spark plug, always thread it in by hand until it seats. Torque the spark plug to 38 Nm (28 lb-ft).

3. Return the generator set control to the desired setting when finished performing maintenance.

Page 88

5. Maintenance 8-2017

This page is intentionally blank.

Page 89

6 Troubleshooting

6.1 Avoiding Generator Set Shutdowns

By regularly performing the following periodic maintenance and guidelines, you will greatly reduce the chances of a generator set shutdown:

• Maintain an appropriate oil level.

• Keep battery connections clean and tight.

• Do not overload the generator set.

• Keep the air inlet and outlet openings clear.

Refer to the Maintenance section for more information.

6.2 Fault Code Introduction

Fault code information, together with warning and shutdown information, is provided in this section to assist in locating and identifying the possible causes of faults in the generator set system.

Refer also to the engine-specific operator manual, if it exists. The engine operator manual contains additional information regarding the running and care of the generator set as well as specific equipment instructions that may differ from the standard generator set.

For any fault codes that occur but are not listed, contact your Cummins service representative.

6.3 Engine Is Difficult to Start or Does Not Start

Possible Causes:

1. Battery voltage problem(s)

2. Fuel system issue(s)

3. Air intake restriction above specification

Diagnosis and Repair:

1. Battery voltage problem(s)

a. If battery voltage is low, interrupted, or open, check:

• Battery connections

• Unswitched battery supply circuit

• Fuses

2. Fuel system issue(s)

a. Verify that the manual fuel shutoff valve is open.

Page 90

6. Troubleshooting 8-2017

3. Air intake restriction above specification

a. Inspect air filter for obstruction. Replace if necessary.

6.4 Code 143 - Engine Oil Pressure Low (Warning)

Logic: Engine oil pressure is below the low oil pressure warning threshold.

Possible Causes:

1. Lubricating oil level is low

2. External leak

Diagnosis and Repair:

1. Lubricating oil level is low

a. Check the oil level. Add oil, if necessary.

2. External leak

a. Inspect the engine and surrounding area for external oil leaks.

b. If a leak is present, contact your Cummins service representative.

6.5 Codes 146 and 151 - Engine Coolant Temperature High (Warning or Shutdown)

Logic:

• Code 146: Engine coolant temperature has exceeded the warning threshold and duration parameters set in the ECM or control.

• Code 151: Engine coolant temperature has exceeded the shutdown (alarm) threshold for high coolant temperature.

Possible Causes:

1. High ambient temperature

2. Enclosure air intake blocked

3. Coolant level below specification

4. Blocked radiator

5. Blocked enclosure air discharge

6. Broken or loose fan belt

Diagnosis and Repair:

1. High ambient temperature

a. Reduce loads or recirculation of discharge air to generator set.

2. Blocked enclosure air discharge

a. Inspect for dirt, debris, or obstructions.

b. Remove blockage or snow/ice buildup if applicable.

Page 91

6. Troubleshooting8-2017

3. Coolant level below specification

a. Check coolant level.

b. Add coolant if applicable.

4. Blocked radiator

a. Inspect for dirt, debris, or obstruction.

b. Remove blockage or winterfront if applicable.

5. Enclosure air discharge blocked

a. Inspect for dirt, debris, or obstructions.

b. Remove blockage or snow/ice buildup if applicable.

6. Broken or loose fan belt

a. Inspect belt(s) for damage, wear, and proper tension.

b. Repair or replace belt(s) if damaged or worn.

6.6 Code 155 - Intake Manifold Temperature High (Shutdown)

Logic: The engine intake manifold temperature has exceeded the temperatures below for greater than 10 seconds:

• Models C45 N6, C50 N6 and C60 N6: 75 °C (167 °F)

• Models C70 N6, C80 N6 and C100 N6: 80 °C (176 °F)

Diagnosis and Repair:

For the troubleshooting procedure, refer to DTC 127 in the E-Controls Manual, which applies to several applications. See the drawings provided with the generator set or the wiring diagrams appendix for the appropriate pin numbers.

6.7 Code 197 - Coolant Level Low (Warning)

Logic: Coolant level sensor signal is showing a low coolant level for greater 10

seconds.

Possible Cause:

1. Low coolant

Diagnosis and Repair:

1. Low coolant

a. Remove radiator cap and check that coolant is up to the required level.

Page 92

6. Troubleshooting 8-2017

6.8 Code 415 - Engine Oil Pressure Low (Shutdown)

Logic:

Engine oil pressure is below 26 psig (180 kpa) for greater than 10 seconds.

Possible Cause:

1. Lubricating oil level is low

2. External leak

Diagnosis and Repair:

1. Lubricating oil level is low

a. Check the oil level. Add oil, if necessary.

2. External leak

a. Inspect the engine and surrounding area for external oil leaks.

b. Contact your local dealer if a leak is present.

6.9 Code 441 - Battery Voltage Low (Warning)

Logic: Battery voltage is low.

Possible Causes:

1. Loose or damaged battery cable connections

2. Battery charger not connected (if equipped)

3. Battery not completely charged

4. Battery is old and does not maintain a charge

Diagnosis and Repair:

1. Loose or damaged battery cable connections

• Inspect the battery cable connections for corrosion and loose connections. Adjust or repair if needed.

2. Battery charger not connected (if equipped)

a. Make sure that the battery charger is connected to the AC power supply.

b. Make sure that the battery charger is connected correctly to the battery.

3. Battery not completely charged

• Using a voltmeter or multimeter, determine if the voltage is below 11 V. If so, recharge the battery.

4. Battery is old and does not maintain a charge

• Replace the battery.

Page 93

6. Troubleshooting8-2017

6.10 Code 488 - Intake Manifold Temperature High (Warning)

Logic:

The engine intake manifold temperature has exceeded the temperatures below for more than 90 seconds:

• Models C45 N6, C50 N6 and C60 N6: 158 °F (70 °C)

• Models C70 N6, C80 N6 and C100 N6: 167 °F (75 °C)

Possible Causes:

1. High ambient temperature

2. Enclosure air intake blocked

3. Coolant level is below specification

4. Radiator blocked

5. Enclosure air discharge blocked

6. Fan belt is broken or loose

Diagnosis and Repair:

1. High ambient temperature

a. Reduce loads or recirculation of discharge air to generator in elevated

ambient.

2. Enclosure air intake blocked

a. Inspect for dirt, debris, or obstructions.

b. Remove blockage or snow/ice buildup as applicable.

3. Coolant level is below specification

a. Check coolant level.

b. Add coolant as necessary.

4. Radiator blocked

a. Inspect for dirt, debris or obstructions.

b. Remove blockage or winterfront as applicable.

5. Enclosure air discharge blocked

a. Inspect for dirt, debris, or obstructions.

b. Remove blockage or snow/ice buildup as applicable.

6. Fan belt is broken or loose

a. Inspect belt(s) for damage, wear, and proper tension.

b. Repair or replace if damaged or worn.

Page 94

6. Troubleshooting 8-2017

6.11 Code 1438 - Fail to Crank (Shutdown)

Logic:

The engine failed to crank after the generator control received a start signal.

Possible Cause:

1. Dead or weak battery

2. Failed starter

Diagnosis and Repair:

1. Dead or weak battery

a. Verify battery voltage is at least 12 VDC (or 24 VDC if applicable).

b. Charge or replace the battery as necessary.

2. Failed starter

a. Press the Reset/Fault acknowledge button on the display.

b. Attempt to start the generator and test for B+ at the starter supply lug.

c. If B+ is present at the starter supply lug, the starter could be defective.

6.12 Code 1472 - High AC Current (Shutdown)

Logic:

The generator output current has exceeded at least 150% of rated current.

Possible Causes:

1. Generator set overload

Diagnosis and Repair:

1. Generator set overload.

a. Reduce the generator set load by powering off to unnecessary household

appliances (examples: washer, dryer, air conditioning, etc.).

6.13 Code 5134 - Unknown Shutdown at Idle

Logic:

Engine is not getting a proper fuel supply.

Possible Causes:

1. Fuel supply issue

Diagnosis and Repair:

1. Fuel supply issue

a. Check that there is a proper supply of fuel to the engine.

Page 95

Page 96

power.cummins.com

trademarks of Cummins Inc. Other company, product, or service names may be trademarks or service

marks of others. Specifications are subject to change without notice.