Operator Manual Generator Set with QSJ5.9G Engine and PowerCommand® 1.
Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1.1 Warning, Caution, and Note Styles Used in This Manual ...................................................... 1.2 General Information ................................................................................................................ 1.3 Generator Set Safety Code .............................................................................................
Table of Contents 9-2015 6.5 Air Intake System.................................................................................................................. 6.6 Batteries................................................................................................................................ 6.7 Spark Plugs .......................................................................................................................... 76 78 82 7. TROUBLESHOOTING ......................................
1 Important Safety Instructions Save these instructions. This manual contains important instructions that should be followed during installation and maintenance of the generator set. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. 1.
1. Important Safety Instructions 9-2015 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.
9-2015 1. Important Safety Instructions 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 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.
1. Important Safety Instructions 9-2015 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-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels.
-2015 1. Important Safety Instructions WARNING Combustible Gases Batteries can explode, causing severe skin and eye burns, and can release toxic electrolytes. Do not dispose of the battery in a fire, because it is capable of exploding. Do not open or mutilate the battery. WARNING Electric Shock Hazard Batteries present the risk to high short circuit current. Remove watches, rings, or other metal objects. Use tools with insulated handles. • Wear safety glasses. • Do not smoke.
1. Important Safety Instructions 1.6 9-2015 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.
9-2015 1. Important Safety Instructions 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.
1. Important Safety Instructions 9-2015 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.
9-2015 1. Important Safety Instructions 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.
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2 Introduction WARNING Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Make sure that only a trained and experienced electrician makes generator electrical output connections, in accordance with the installation instructions and all applicable codes. WARNING Electrical Generating Equipment Faulty electrical generating equipment can cause severe personal injury or death.
2. Introduction 9-2015 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. 2.2 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.
9-2015 2. Introduction ABBR. CMM CT D-AVR DESCRIPTION ABBR.
2. Introduction 9-2015 ABBR. 2.3 DESCRIPTION ABBR. LBNG Lean-burn Natural Gas UL LCD Liquid Crystal Display UPS DESCRIPTION Underwriters Laboratories Uninterruptible Power Supply 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.
9-2015 2. Introduction • 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 2.4 Model Specifications NOTICE Damage caused by failure to follow the manufacturer's recommendation will not be covered by the warranty. Please contact your authorized distributor. TABLE 1. 5.
2. Introduction 9-2015 TABLE 3. FUEL SPECIFICATIONS 60 HZ, 1800 RPM Type Unit C45 N6 C50 N6 C60 N6 C70 N6 C80 N6 C100 N6 Liquid Propane Full Load scfh 289.6 321.6 370.2 384.2 420.8 518.7 BTU/hr 651,600 723,600 832,950 864,450 946,800 1,167,075 scfh 711.2 806.3 933.8 988.4 1,083.5 1,317.7 BTU/hr 721,868 818,395 947,807 Natural Gas Full Load Fuel Pressure 1,003,226 1,099,753 1,337,466 Minimum: 6 inches water column (1.5 kPa) Maximum: 14 inches water column (3.
9-2015 2. Introduction Type Specification • Must adhere to Cummins® Engineering Standard (CES) 20074 • Use of improper oils can result in engine damage. Use only the required oils: ◦ 5W-40 (all ambient temperatures) ◦ 15W-40 (above 40 °F [4 °C] ambient temperature) (use of GEO 15W-40 oil in ambient temperatures below 40 °F [4 °C] could result in engine turbocharger damage) Oil Standards • A sulfated ash limit of 0.
2. Introduction 9-2015 TABLE 7. Type GENERATOR SPECIFICATIONS 60 HZ, 1800 RPM C45 N6 C50 N6 Generator C60 N6 C70 N6 C80 N6 C100 N6 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%.
9-2015 2. Introduction TABLE 9. 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 10.
2. Introduction 9-2015 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 local dealer. Maintenance tasks should only be undertaken by trained and experienced technicians provided by your authorized dealer.
9-2015 2. Introduction • Keep areas clear in front of the cool air in and hot air out (free of obstructions, debris, plants, etc.). No. Description No. Description 1 Cool Air In 3 2 Hot Air Out (Sound Level Enclosure) FIGURE 1. Hot Air Out (Weather Enclosure) GENERATOR SET LOCATION NOTICE All maintenance procedures must be performed or supervised by authorized and trained service personnel only. 2.
2. Introduction 9-2015 Model, Spec, and Serial Numbers: Be ready to provide the model, spec, and serial numbers on the generator set nameplate when contacting Cummins Power Generation 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.
3 Manufacturing Facilities NORTH AMERICA EMEA, CIS ASIA PACIFIC Cummins Power Generation Limited 1400 73rd Ave.
3. Manufacturing Facilities 9-2015 This page is intentionally blank.
4 Control System 4.1 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.
4. Control System 9-2015 FIGURE 2. STANDARD OPERATOR PANEL (HMI211) Standard Key Functions (HMI211) The user interface includes two fixed action buttons and four soft key buttons. The action of the soft key buttons changes to meet the requirements of each screen. TABLE 12. Key/Symbol KEY FUNCTIONS Action Switches to Off mode (fixed action button). Switches to Auto mode. Switches to Manual Run mode. Navigates to the previous menu level (fixed action button).
9-2015 4. Control System Key/Symbol Action - Decreases value of the highlighted editable field. + Increases value of highlighted editable field. Standard LED Indicators (HMI211) The operator panel has six LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below. TABLE 13. LED Color LED INDICATORS Action Not in Auto Red Indicates the generator set is in Manual or Off Mode. Shutdown Red Indicates a Shutdown Fault has occurred.
4. Control System 9-2015 FIGURE 3. IN-HOME OPERATOR PANEL Key Functions (In-Home Operator Panel) The user interface includes two fixed action buttons and four soft key buttons. The action of the soft key buttons changes to meet the requirements of each screen. TABLE 14. Key/Symbol Stop KEY FUNCTIONS Action Switches to Off mode. This key works from any screen (fixed action button). (Up Arrow) Navigates to the previous screen/menu in a list. (Down Arrow) Navigates to the next screen/menu in a list.
9-2015 4. Control System LED Indicators (In-Home Operator Panel) The operator panel has five LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below. TABLE 15. LED Color Shutdown Red LED INDICATORS Action Indicates a Shutdown Fault has occurred. Warning Yellow Indicates a Warning Fault has occurred. Auto Start Green Indicates that the generator set has received a Remote Start Command.
4. Control System 9-2015 Symbol Text Battery Out of Range High or Pre-High Low or Pre-Low Annunciator Over Speed Crank Fail Emergency Stop 4.3 Exercise Settings NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without an RA series transfer switch. To access the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2.
9-2015 4. Control System FIGURE 4.
4. Control System 9-2015 Updating Exercise Frequency 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.
9-2015 4. Control System FIGURE 5. EXERCISE FREQUENCY NAVIGATION Updating Exercise Duration 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.
4. Control System 9-2015 • Press Save to save any changes. After saving, the Save button changes to the Adjust button. FIGURE 6. EXERCISE DURATION NAVIGATION Time Setup 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.
9-2015 4. Control System FIGURE 7. TIME SETUP SCREEN Updating Daylight Saving Adjust Screen To update the Time and Adjustment 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. 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.
4. Control System 9-2015 FIGURE 8. DAYLIGHT SAVING ADJUST SCREEN NAVIGATION To access and update the Daylight Saving Adjust Start screen: 1. Press the down key on the Daylight Saving Adjust screen. 2. 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: ◦ Month ◦ Week ◦ Day ◦ Hour • Press Save to save any changes.
9-2015 4. Control System FIGURE 9. DAYLIGHT SAVING ADJUST START SCREEN To access and 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: • 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: ◦ Month ◦ Week ◦ Day ◦ Hour • Press Save to save any changes.
4. Control System 9-2015 FIGURE 10. 4.4 DAYLIGHT SAVING ADJUST END SCREEN Brightness and Contrast The Screen Adjust screen allows the contrast, brightness, and units to be set. To access the Screen Adjust screen: 1. From any Information screen, hold down the up and down arrows simultaneously for two seconds to gain access to the Service Menu screen. 2. Select Screen Adjust. To adjust the contrast, brightness, or units from the Screen Adjust screen: 1.
9-2015 4. Control System NOTICE The following screens represent the standard operator panel (HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels. FIGURE 11.
4. Control System 9-2015 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%. 4.5 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.
9-2015 4. Control System FIGURE 12.
4. Control System 4.6 9-2015 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.
9-2015 4. Control System FIGURE 13.
4. Control System 4.7 9-2015 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.
9-2015 4. Control System No. Description No. Description 1 Menu Displayed Only When the Mode Change Access Code Feature Is Enabled 2 Alternating Arrows Displayed FIGURE 14.
4. Control System 9-2015 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.
9-2015 4. Control System No. Description No. Description 1 This Menu Is Displayed Only if the Mode Change Access Code Feature Is Enabled 2 Alternating Arrows Are Displayed FIGURE 15.
4. Control System 9-2015 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.
9-2015 4. Control System No. Description 1 No. Description Off Button 2 FIGURE 16. 4.8 This Mode Is Displayed Only if the Mode Change Access Code Feature Is Enabled SELECTING OFF MODE Operating Modes The generator set control works with a Manual Run/Off/Auto switch, used to control generator set operating modes.
4. Control System 9-2015 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.
5 Operation - PowerCommand 1.1 5.1 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. 5.2 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.
5. Operation - PowerCommand 1.1 9-2015 NOTICE Cummins Power Generation 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.
9-2015 5. Operation - PowerCommand 1.1 NOTICE The control box area is equipped with an ambient temperature sensor for controlling the idle feature. Do not install any heaters in the control box area as this can influence the sensor and lead to engine damage. 5. After the generator set ramps up to rated speed, the generator set provides voltage to the transfer switch, but the transfer switch does not switch (allowing the voltage to go to the building) until after a delay. FIGURE 18.
5. Operation - PowerCommand 1.1 9-2015 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.
9-2015 5. Operation - PowerCommand 1.1 2. If the ambient temperature is below 20 °F (6.7 °C), the generator set will idle at 800 rpm for up to 2 minutes to allow sufficient turbo lubrication. • Idle time is linear from 2 minutes at -40 F (4 °C), or below to off at 20 °F (6.7 °C) or above. FIGURE 25. COLD START IDLE ACTIVE 3. The Exerciser Scheduler On screen displays every 3 seconds and toggles between the existing Information screen that is displayed for 1 second. FIGURE 26.
5. Operation - PowerCommand 1.1 9-2015 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.
9-2015 5. Operation - PowerCommand 1.1 FIGURE 28. COLD START IDLE ACTIVE 5. The generator set provides voltage to the transfer switch. (However, the transfer switch does not transfer in manual mode.) Remote Starting the Generator Set Sequence If the generator set is remote started with the in-home operator panel accessory, if equipped (the generator set is in Auto Mode), the sequence is as follows: 1.
5. Operation - PowerCommand 1.1 FIGURE 29. 9-2015 HMI211 SET IN AUTO MODE 3. Manually start the generator set via the in-home operator panel.
9-2015 5. Operation - PowerCommand 1.1 FIGURE 30. MANUAL START SCREEN, IN-HOME OPERATOR PANEL 4. The generator set starts and provides voltage to the transfer switch, but the transfer switch does not switch (allowing the voltage to go to the building) until after a delay. FIGURE 31. TIME REMAINING UNTIL TRANSFER SCREEN 5. Five seconds after starting, the generator set provides a signal to the transfer switch to transfer the building load to the generator set.
5. Operation - PowerCommand 1.1 FIGURE 32. 9-2015 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 (4 °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.
9-2015 5. Operation - PowerCommand 1.1 FIGURE 36. UTILITY POWERING BUILDING LOAD 9. The generator set runs for a 5-minute cooldown and shuts off. FIGURE 37. TIME REMAINING UNTIL STOP 10. Normal operation resumes.
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6 Maintenance 6.1 Maintenance Safety WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery cables (negative [–] first). WARNING Hydrogen Gas Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury or death.
6. Maintenance 9-2015 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.
9-2015 6. Maintenance 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 mode switch on the Operator Panel to shut down the engine. 2. Press the Emergency Stop button (if applicable).
6. Maintenance 9-2015 The periodic maintenance procedures should be performed at whichever interval occurs first (calendar time or hours of operation). At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance.
9-2015 6. Maintenance TABLE 17. Maintenance Items PERIODIC MAINTENANCE SCHEDULE After Every After Every 12 Months or 24 Hours 50 Hours After 250 of Run of Run Hours2 1 Time Time Check air cleaner restriction indicator (where fitted): If the indicator shows red, replace air cleaner element and reset the indicator. ■ 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.
6. Maintenance Maintenance Items 9-2015 After Every After Every 12 Months or 24 Hours 50 Hours After 250 of Run of Run Hours2 1 Time Time 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. ■ Check all exhaust components and hardware (fittings, clamps, fasteners, etc.
9-2015 Maintenance Items 6. Maintenance After Every After Every 12 Months or 24 Hours 50 Hours After 250 of Run of Run Hours2 1 Time Time Check water pump for leaks. Check weep holes for evidence of leaks. Replace if leaking. ■ 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.
6. Maintenance Maintenance Items 9-2015 After Every After Every 12 Months or 24 Hours 50 Hours After 250 of Run of Run Hours2 1 Time Time Check engine mounts for general condition and for signs of excessive wear. ■ 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.
9-2015 6. Maintenance 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. 6.
6. Maintenance 9-2015 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. Accidental or remote starting of the generator set can cause severe personal injury or death. Disconnect the negative (-) battery cable and place the control switch in its OFF position before starting work.
9-2015 6. Maintenance No. Description No. Description 1 Fill Cap 3 Oil Filter 2 Dipstick 4 Oil Drain Hose FIGURE 38. ENGINE OIL COMPONENTS To check the engine oil level: 1. Make sure that the engine has not been running for approximately five minutes. 2. Clean off the area surrounding the dipstick port to prevent entry of debris into the oil pan. 3. Pull out the dipstick and wipe it clean. 4. Reinsert and fully seat the dipstick. 5. Remove the dipstick and check the oil level.
6. Maintenance 9-2015 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.
9-2015 6. Maintenance Changing Engine Oil and Oil Filter 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. Accidental or remote starting of the generator set can cause severe personal injury or death. Disconnect the negative (-) battery cable and place the control switch in its OFF position before starting work.
6. Maintenance 9-2015 8. Operate the engine at idle to inspect for leaks at the lubricating oil filter and the drain plug. 9. 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. 10. Check and repair any leaks identified. 11. Dispose of the used oil and oil filter according to local environmental regulations. 6.
9-2015 6. Maintenance No. Description 1 No. Description Air Cleaner 2 FIGURE 39. Strap Clamp NORMAL DUTY AIR CLEANER Heavy Duty Air Cleaner Element Replacement 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.
6. Maintenance 9-2015 No. Description No. Description 1 Housing 3 Latch 2 Air Filter Element 4 End Cover FIGURE 40. 6.6 HEAVY DUTY AIR CLEANER Batteries Batteries are an essential part of any standby generator 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.
9-2015 6. Maintenance Filled and charged batteries must be stored in a cool, dry, well-ventilated place. Make sure that the vent caps are securely screwed down or pushed home. 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 Handling and proper use of batteries is not hazardous if the correct precautions are observed and personnel are trained in their use.
6. Maintenance 9-2015 CAUTION Fire Hazard 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. NOTICE Make sure that batteries are charged in a well ventilated area, away from naked flames and sparks.
9-2015 6. Maintenance 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.
6. Maintenance 9-2015 Battery Replacement WARNING Combustible Liquid Burning the battery may cause an explosion. Damage to the casing will release electrolytes which is harmful to the skin and eyes. When disposing of a battery, do not mutilate or burn it. Comply with all local health and safety regulations/codes during handling or disposal. Always replace the starting battery with the same number and type (e.g. vented, lead acid, maintenance free).
7 Troubleshooting The following list of codes is not an all inclusive list. For more information about the fault codes listed or for additional codes, contact your local dealer. NOTICE Make sure service personnel are qualified to perform electrical and mechanical service. 7.2 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.
7. Troubleshooting 9-2015 2. External leak. a. Inspect the engine and surrounding area for external oil leaks. b. Contact your local dealer if a leak is present. 7.4 Code 151 - Engine Coolant Temperature High (Shutdown) Logic: Engine coolant temperature has exceeded the alarm (shutdown) threshold for high coolant temperature. Possible Cause: 1. High ambient temperature 2. Enclosure air intake blocked 3. Coolant level is below specification 4. Radiator blocked 5. Enclosure air discharge blocked 6.
9-2015 7. Troubleshooting b. Repair or replace if damaged or worn. 7. Coolant level is below specification a. Check coolant level. b. Add coolant as necessary. 7.
7. Troubleshooting 9-2015 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. 7.8 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.
9-2015 7. Troubleshooting 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.
7. Troubleshooting 9-2015 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. 7.
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