Operator Manual Generator Set QSJ2.4 Engine with PowerCommand® 1.
Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1.1 Warning, Caution, and Note Styles Used in This Manual ...................................................... 1.2 General Information ................................................................................................................ 1.3 General Safety Precautions.............................................................................................
Table of Contents 2-2016 5.7 Spark Plugs .......................................................................................................................... 81 6. TROUBLESHOOTING ................................................................................................................. 6.1 Engine Is Difficult to Start or Does Not Start ........................................................................ 6.2 Code 143 - Engine Oil Pressure Low (Warning) ...................................
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 1.3 2-2016 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.
2-2016 1. Important Safety Instructions WARNING High Noise Level Generator sets in operation emit noise, which can cause hearing damage. Wear appropriate ear protection at all times. WARNING Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.
1. Important Safety Instructions 2-2016 WARNING Fire Hazard Materials drawn into the generator set are a fire hazard. Fire can cause severe burns or death. Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit. WARNING Fire Hazard 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. Repair oil leaks promptly.
2-2016 1.4 1. Important Safety Instructions 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.
1. Important Safety Instructions 2-2016 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. NOTICE Servicing of batteries is to 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. • To prevent arcing when disconnecting the battery: 1. Press the Stop switch.
2-2016 1.7 1. Important Safety Instructions 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.
1. Important Safety Instructions 2-2016 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. 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.
2-2016 1.9 1. Important Safety Instructions The Hazards of Carbon Monoxide Carbon monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas. You cannot see it or smell it. Red blood cells, however, have a greater affinity for CO than for oxygen. Therefore, exposure even to low levels of CO for a prolonged period can lead to asphyxiation (lack of oxygen) resulting in death.
1. Important Safety Instructions 2-2016 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.
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 2-2016 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 Icons The following symbols may have been used in this manual to help communicate the intent of the instructions. They are defined below. Icon Description Clean the part or assembly.
2-2016 2. Introduction Icon Description Indicates parts or tools required. Indicates that the component is heavy (50 lb or 23 kg or more). To reduce the possibility of personal injury, use a hoist or get assistance to lift. 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.
2. Introduction 2-2016 ABBR. CMM CT D-AVR DESCRIPTION ABBR.
2-2016 2. Introduction ABBR. 2.4 DESCRIPTION ABBR. LBNG Lean-burn Natural Gas UL LCD Liquid Crystal Display UPS DESCRIPTION Underwriters Laboratories Uninterruptible Power Supply Related Literature The literature provided with the generator set is as follows: • Installation Manual (A045R241) • Operator Manual (A045R242) CAUTION A generator set must be operated and maintained properly if you are to expect safe and reliable operation.
2. Introduction 2.5 2-2016 Model Specifications TABLE 1. 2.4L MODEL VARIATIONS Models Description C20 N6, C22 N6, C25 N6, C30 N6, C36 N6, C40 N6 60 Hz, 1800 RPM C30 N6H, C36 N6H, C40 N6H, C45 N6H, C50 N6H, C60 N6H 60 Hz, 3600 RPM TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS) Temperature Description Battery Type Group Above 40 °F (4 °C) No starting aids required. Standard 26 0 to 40 °F (-17 to 4 °C) Additional coolant heater and battery charger recommended for starting.
2-2016 2. Introduction C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 C40 N6 6 - 12 inch water column (1.5 - 3.0 kPa) Maximum pressure under any condition: 13 inch water column (3.2 kPa) Fuel Pressure TABLE 4. FUEL SPECIFICATIONS 60 HZ, 3600 RPM C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H Full Load (Propane) 195.5 scfh 490,000 BTU/hr 219.6 scfh 550,000 BTU/hr 236.2 scfh 595,000 BTU/hr 256.9 scfh 645,000 BTU/hr 289.5 scfh 725,000 BTU/hr 324.6 scfh 820,000 BTU/hr Full load (Natural Gas) 476.
2. Introduction 2-2016 TABLE 7. GENERATOR SET WEIGHT (POUNDS) 60 HZ, 1800 RPM C20 N6 C22 N6 C25 N6 C30 N6 C36 N6 C40 N6 1109 1109 1147 1279 1356 1424 Sound Level 1 (Wet) TABLE 8. GENERATOR SET WEIGHT (POUNDS) 60 HZ, 3600 RPM C30 N6H C36 N6H C40 N6H C45 N6H C50 N6H C60 N6H 1134 1249 1399 1399 1399 1429 Sound Level 1 (Wet) TABLE 9.
2-2016 2. Introduction TABLE 11. GENERATOR SET DERATING GUIDELINES Engine Power Available Up To... Model Fuel Elevation Ambient Temperature C20 N6 NG, LP 3300 ft (1005 m) 104 °F (40 °C) C22 N6 NG 2200 ft (670.
2. Introduction 2-2016 TABLE 12. CONTROL SPECIFICATIONS (ALL MODELS) Specification Control Integrated microprocessor based engine, generator, transfer switch control TABLE 13.
2-2016 2. Introduction 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 customer access door on enclosed generator sets. 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.
2. Introduction 2-2016 No. Description 1 No. Description Cool Air In 2 FIGURE 1. Hot Air Out GENERATOR SET LOCATION NOTICE All maintenance procedures must be performed or supervised by authorized and trained service personnel only. Copyright © 2016 Cummins Inc.
3 Control System 3.1 Control System Description The control system is used to start and stop the generator set, and provides full generator set monitoring capability and protection in a stand-alone situation (nonparalleling) from the display screen. It monitors the engine for temperature, as well as oil pressure and speed. It also provides voltage and current metering. In the event of a fault, the unit indicates the fault type and, on critical faults, automatically shuts down the generator set.
3. Control System 2-2016 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 14. Key/Symbol KEY FUNCTIONS Action Switches to Off mode (fixed action button). Switches to Auto mode. Switches to Manual Run mode. Navigates to the previous menu level (fixed action button).
2-2016 3. Control System Key/Symbol Action - Decreases value of the highlighted editable field. + Increases value of highlighted editable field. Standard LED Indicators (HMI211) The operator panel has six LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below. TABLE 15. LED Color LED INDICATORS Action Not in Auto Red Indicates the generator set is in Manual or Off Mode. Shutdown Red Indicates a Shutdown Fault has occurred.
3. Control System 2-2016 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 16. Key/Symbol Stop KEY FUNCTIONS Action Switches to Off mode. This key works from any screen (fixed action button). (Up Arrow) Navigates to the previous screen/menu in a list. (Down Arrow) Navigates to the next screen/menu in a list.
2-2016 3. Control System LED Indicators (In-Home Operator Panel) The operator panel has five LED indicators. Colors, flashing frequency, and conditions to turn them on/off/blink are included in the table below. TABLE 17. LED Color Shutdown Red LED INDICATORS Action Indicates a Shutdown Fault has occurred. Warning Yellow Indicates a Warning Fault has occurred. Auto Start Green Indicates that the generator set has received a Remote Start Command.
3. Control System 2-2016 Symbol Text Battery Out of Range High or Pre-High Low or Pre-Low Annunciator Over Speed Crank Fail Emergency Stop 3.3 Exercise Settings NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without a single phase RA series transfer switch. To access the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2.
2-2016 3. Control System FIGURE 4. A045R242 (Issue 7) CLOCK/EXERCISER MENU NAVIGATION 29 Copyright © 2016 Cummins Inc.
3. Control System 2-2016 Updating Exercise Frequency NOTICE Not applicable without a single phase RA series transfer switch. To update the exercise frequency and dates on the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3. Press the down key on the Time Setup screen to access the Daylight Saving Adjust screen. 4.
2-2016 3. Control System FIGURE 5. EXERCISE FREQUENCY NAVIGATION Updating Exercise Duration NOTICE Not applicable without a single phase RA series transfer switch. To update the exercise duration on the Clock/Exerciser Menu: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Access the Time Setup screen by selecting Clock Exerciser on the Genset Service Menu. 3.
3. Control System 2-2016 • Press Save to save any changes. After saving, the Save button changes to the Adjust button. FIGURE 6. 3.4 EXERCISE DURATION NAVIGATION Time Setup NOTICE When battery power is lost, these settings must be reset. NOTICE Not applicable without a single phase RA series transfer switch. To set up the generator set clock for the current date and time: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2.
2-2016 3. Control System • Press Save to save any changes. After saving, the Save button changes to the Adjust button. 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.
3. Control System 2-2016 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.
2-2016 3. 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.
3. Control System 2-2016 FIGURE 10. 3.5 DAYLIGHT SAVING ADJUST END SCREEN Brightness and Contrast The Screen Adjust screen allows the contrast, brightness, and units to be set. To access the Screen Adjust screen: 1. From any Information screen, hold down the up and down arrows simultaneously for two seconds to gain access to the Service Menu screen. 2. Select Screen Adjust. To adjust the contrast, brightness, or units from the Screen Adjust screen: 1.
2-2016 3. Control System NOTICE The following screens represent the standard operator panel (HMI211). If using an in-home operator panel, which may be additionally purchased as an option, the screens may look slightly different. This procedure applies to both operator panels. FIGURE 11. A045R242 (Issue 7) BRIGHTNESS AND CONTRAST SCREEN NAVIGATION 37 Copyright © 2016 Cummins Inc.
3. Control System 2-2016 NOTICE Adjusting the brightness on the operator panel adjusts the brightness of both the LCD backlight and the LEDs on the display. The contrast should never be 0 or 100% on any of the screens. The default value for Brightness is 50%. 3.6 History and About Menu To access the History/About screen: 1. From any Information Menu, hold down the up and down arrows simultaneously for two seconds. The Service Menu appears. 2. Select History/About. 3.
2-2016 3. Control System FIGURE 12. A045R242 (Issue 7) HISTORY/ABOUT MENU 39 Copyright © 2016 Cummins Inc.
3. Control System 3.7 2-2016 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.
2-2016 3. Control System FIGURE 13. A045R242 (Issue 7) FAULT LOG SCREEN 41 Copyright © 2016 Cummins Inc.
3. Control System 3.8 2-2016 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.
2-2016 3. Control System No. Description No. Description 1 Menu Displayed Only When the Mode Change Access Code Feature Is Enabled 2 Alternating Arrows Displayed FIGURE 14. A045R242 (Issue 7) 3 Manual Run Mode Selected SELECTING MANUAL RUN MODE 43 Copyright © 2016 Cummins Inc.
3. Control System 2-2016 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 45), 1. Ensure that it is safe to do so before proceeding to change the mode. 2.
2-2016 3. Control System No. Description No. Description 1 This Menu Is Displayed Only if the Mode Change Access Code Feature Is Enabled 2 Alternating Arrows Are Displayed FIGURE 15. A045R242 (Issue 7) 3 Auto Mode Selected SELECTING AUTO MODE 45 Copyright © 2016 Cummins Inc.
3. Control System 2-2016 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.
2-2016 3. Control System No. Description 1 No. Description Off Button 2 FIGURE 16. 3.9 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. A045R242 (Issue 7) 47 Copyright © 2016 Cummins Inc.
3. Control System 2-2016 Off Mode When in Off mode, the control does not allow the generator set to start. If the generator set is already running and the control is set to Off, it initiates a normal shutdown sequence. Manual Run Mode When in Manual Run mode, the generator set starts and continues to run until the control is put into the Off mode. While in Manual Run mode, the remote start signal is ignored.
4 Operation - PowerCommand 1.1 4.1 Sequence of Operation NOTICE The following sequences are based on an approximate time duration. Your generator set may vary slightly from the timing diagrams in this manual. All referenced times are based on default control settings. The following sequences are applicable to generator sets connected to a single phase RA series transfer switch.
4. Operation - PowerCommand 1.1 FIGURE 18. 2-2016 BUILDING LOAD TRANSFER IN PROCESS 6. The transfer switch switches the generator set power to the building load. The building is now running on generator power. FIGURE 19. GENERATOR SET POWERING BUILDING LOAD 7. When the utility power is back and providing voltage to the transfer switch, the transfer switch waits for utility power stability. FIGURE 20. TIME REMAINING UNTIL RE-TRANSFER 8.
2-2016 4. Operation - PowerCommand 1.1 FIGURE 22. UTILITY POWERING BUILDING LOAD 9. The generator set runs for a 5-minute cooldown and shuts off. FIGURE 23. TIME REMAINING UNTIL STOP 10. 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. 2.
4. Operation - PowerCommand 1.1 2-2016 4. 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: NOTICE Open the generator set main line circuit breaker to prevent the transfer switch from transferring building load to the generator set. 1.
2-2016 4. Operation - PowerCommand 1.1 FIGURE 26. BUILDING LOAD TRANSFER IN PROCESS 5. The transfer switch switches the generator set power to the building load. The building is now running on generator power. FIGURE 27. GENERATOR SET POWERING BUILDING LOAD 6. Press the Off button to switch the load back to the utility power. FIGURE 28. BUILDING LOAD TRANSFER IN PROCESS FIGURE 29. UTILITY POWERING BUILDING LOAD 7. Normal operation resumes. A045R242 (Issue 7) 53 Copyright © 2016 Cummins Inc.
4. Operation - PowerCommand 1.1 2-2016 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. FIGURE 30. HMI211 SET IN AUTO MODE 3.
2-2016 4. Operation - PowerCommand 1.1 FIGURE 31. 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 32. TIME REMAINING UNTIL TRANSFER SCREEN 5. Five seconds after starting, the generator set provides a signal to the transfer switch to transfer the building load to the generator set.
4. Operation - PowerCommand 1.1 FIGURE 33. 2-2016 BUILDING LOAD TRANSFER IN PROCESS 6. The transfer switch switches the generator set power to the building load. The building is now running on generator power. FIGURE 34. GENERATOR SET POWERING BUILDING LOAD 7. When the remote display Stop button is pressed, the transfer switch switches back to utility power after a 5 minute retransfer delay. FIGURE 35. BUILDING LOAD TRANSFER IN PROCESS FIGURE 36. UTILITY POWERING BUILDING LOAD 8.
2-2016 4. Operation - PowerCommand 1.1 FIGURE 37. TIME REMAINING UNTIL STOP 9. Normal operation resumes. A045R242 (Issue 7) 57 Copyright © 2016 Cummins Inc.
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5 Maintenance 5.1 Maintenance Safety WARNING Automated Machinery Accidental or remote starting of the generator set can cause severe personal injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery cables (negative [–] first). WARNING Hydrogen Gas Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury or death.
5. Maintenance 2-2016 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.
2-2016 5. 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).
5. Maintenance 2-2016 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.
2-2016 5. Maintenance TABLE 19. Maintenance Item Daily or After 24 Hours Check air cleaner restriction indicator (where fitted): If the service indicator shows red, replace air cleaner elements and reset the air cleaner service indicator. ■ Check air intake system for leaks: Visually inspect the air intake system for signs of wear or damage. Check audibly when the generator set is running. Replace worn or damaged components.
5. Maintenance Maintenance Item 2-2016 Daily or After 24 Hours Check operation of operator panel: Check display (the system will perform a control panel test on initial activation). Replace component if not functioning properly. ■ Check coolant level of radiator(s) (water jacket & LTA): If low, top up to coolant system specifications level, with Cummins recommende d coolant mix. ■ Check cooling fan blades: Visually inspect the fan blades through the guarding for signs of wear or damage.
2-2016 Maintenance Item 5. Maintenance Daily or After 24 Hours Check drive belt, condition and tension: Visually check belt for evidence of wear or slippage. ■ Check coolant lines and radiator hoses for leaks, wear, and cracks: Visually check for leaks, worn or damaged hoses. ■ Check radiator air flow: Visually inspect the radiator through the guarding for blockage, build-up of debris, signs of wear or damage. ■ Verify that the coolant heater has power and is running (where fitted).
5. Maintenance Maintenance Item 2-2016 Daily or After 24 Hours Check engine oil level: If low, top up to engine specifications level, with recommende d oil. ■ Check fuel lines and hoses: Visually check for leaks, worn or damaged hoses. ■ Check charge alternator: Check visually and audibly when the generator set is running. ■ Check all exhaust components, and hardware (fittings, clamps, fasteners, etc.): Visually inspect the exhaust system for signs of wear or damage.
2-2016 Maintenance Item Check generator set enclosure: Visually check enclosure, walk around inspection of generator set. Make sure no inlets/outlets are covered/restri cted, service access doors are operational and safety systems are in place and operational. 5. Maintenance Daily or After 24 Hours Weekly or After 50 Hours 12 Months or After 200 Hours1 2 Years1 4000 hours ■ Check operation of Emergency Stop Button (where fitted): With the generator set running, press the Emergency Stop button.
5. Maintenance Maintenance Item 2-2016 Daily or After 24 Hours Check battery: Check connections to verify that they are secure. Replace air cleaner. Weekly or After 50 Hours 100 Hours ■ 12 Months or After 200 Hours1 2 Years1 4000 hours ■ ■ Clean radiator core. ■3 Check charge air cooler for damage and debris (where fitted). ■ Check water pump for leaks. Check weep holes for evidence of leaks. Replace if leaking. ■ Check engine ground. Clean as necessary.
2-2016 Maintenance Item 5. Maintenance Daily or After 24 Hours Weekly or After 50 Hours 100 Hours 12 Months or After 200 Hours1 2 Years1 4000 hours Check turbocharger (where fitted) for signs of leakage. Listen for excessive noise when test running the generator set. ■ Check timing belt condition. Visually inspect. ■ Inspect spark plugs. Replace if showing signs of excessive wear, carbon deposits, oil accumulation or damaged. ■ Check battery condition.
5. Maintenance Maintenance Item 2-2016 Daily or After 24 Hours Weekly or After 50 Hours 100 Hours 12 Months or After 200 Hours1 2 Years1 4000 hours Check alternator heater (where fitted). Check general condition and wiring connections. ■ Check battery heater (where fitted). Check general condition and wiring connections. ■ ■ Replace cooling system coolant. ■4 Inspect all sealed bearings every 4000 to 4500 hours 1 – To be performed by a qualified Service Technician.
2-2016 5. Maintenance 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 (5W30 API SM engine oil is recommended).
5. Maintenance 2-2016 No. Description No. Description 1 Fill Cap 3 Dipstick 2 Oil Filter 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.
2-2016 5. Maintenance No. Description 1 No. Description High Oil Level (4.3 L or 4.5 qt) FIGURE 39. 2 Low Oil Level (3.8 L or 4.0 qt) ENGINE OIL DIPSTICK Adding or Draining Oil WARNING Hot Surfaces Contact with hot surfaces can cause severe burns. Wear appropriate PPE when working on hot equipment and avoid physical contact with hot surfaces. WARNING Hot Engines Contact with hot engines can cause severe burns. Ensure that the generator set engine has cooled down before adding or draining the oil.
5. Maintenance 2-2016 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. 3. Recheck the engine oil level. Based on the results, add or drain oil. 4.
2-2016 5. Maintenance NOTICE If the oil and/or oil filter are not reused, dispose of them in accordance with local environmental regulations. NOTICE Change the engine oil and filter when the engine is not running and is out of Auto mode. NOTICE Change the oil more often in hot and dusty environments. NOTICE CPG highly recommends that any service or maintenance work be performed by qualified technicians. 1.
5. Maintenance 5.5 2-2016 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 635 mm of H20 (25 in of H20), at which point the filter elements should be changed.
2-2016 5. Maintenance Normal Duty Air Cleaner Installation Install the air cleaner (1) as follows: 1. Install the air cleaner (1). 2. Tighten strap clamp (2). No. Description 1 No. Description Air Cleaner 2 FIGURE 41. A045R242 (Issue 7) Strap Clamp NORMAL DUTY AIR CLEANER 77 Copyright © 2016 Cummins Inc.
5. Maintenance 2-2016 Heavy Duty Air Cleaner Heavy Duty Air Cleaner Element Removal No. Description No. Description 1 Housing 3 Latch 2 Air Filter Element 4 End Cover FIGURE 42. HEAVY DUTY AIR CLEANER NOTICE Cummins Inc. does not recommend cleaning paper-type air cleaner elements. 1. Before disassembly, wipe dirt from the cover and the upper portion of the air cleaner. 2. Lift tab (3) and turn end cover (4) counterclockwise. 3. Pull the end cover (4) away from the housing (1). 4.
2-2016 5. Maintenance 5. Dispose of the dirty element in accordance with local environmental agency requirements. Heavy Duty Air Cleaner Element Installation No. Description No. Description 1 Housing 3 Latch 2 Air Filter Element 4 End cover FIGURE 43. HEAVY DUTY AIR CLEANER 1. Ensure that no debris enters the filter element or connection point on the air cleaner housing. 2. Insert the air filter element (2) into the housing (1). 3. Install the end cover (4) onto the housing (1). 4.
5. Maintenance 5.6 2-2016 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.
2-2016 5. Maintenance 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.
5. Maintenance 2-2016 This page is intentionally blank. Copyright © 2016 Cummins Inc.
6 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. 6.1 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.
6. Troubleshooting 2-2016 2. External leak. a. Inspect the engine and surrounding area for external oil leaks. b. Contact your local dealer if a leak is present. 6.3 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.
2-2016 6. Troubleshooting b. Repair or replace if damaged or worn. 7. Coolant level is below specification a. Check coolant level. b. Add coolant as necessary. 6.4 Code 155 - Intake Manifold Temperature High (Shutdown) Logic: Engine intake manifold temperature has exceeded 203 °F (95 °C) for greater than 10 seconds. NOTICE The E-controls manual applies to several applications. See the wiring diagrams provided with the generator set or in APPENDIX for appropriate pin numbers.
6. Troubleshooting 2-2016 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. 6.7 Code 421 - Engine Oil Temperature High (Warning) Logic: The control has detected the engine oil temperature has exceeded the warning threshold. Possible Cause: 1. High ambient temperature 2. Enclosure air intake blocked 3.
2-2016 6. Troubleshooting Diagnosis and Repair: 1. Loose or damaged battery cable connections. a. Inspect the battery cable connections. i. Inspect connections for corrosion. ii. Inspect connections for loose connections. 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 needs recharging a.
6. Troubleshooting 2-2016 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. 6.
2-2016 6. Troubleshooting 6.12 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. A045R242 (Issue 7) 89 Copyright © 2016 Cummins Inc.
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7 Manufacturing Facilities Facility Address Phone Numbers NORTH AMERICA Cummins Power Generation Limited 1400 73rd Ave.
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power.cummins.com Copyright © 2016 Cummins Inc. All rights reserved. Cummins Power Generation, the "C" logo, and Cummins are trademarks of Cummins Inc. PowerCommand, AmpSentry, InPower, and "Our energy working for you." are trademarks of Cummins Power Generation Inc. Other company, product, or service names may be trademarks or service marks of others. Specifications are subject to change without notice.