CUMMINS C20N6H (01) PDF MANUAL

The safety styles and symbols 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.

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

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

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. The following precautions should be followed:

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 persons in accordance with the installation instructions and all applicable codes. 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.

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.

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.

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.

High Noise Level: Generator sets in operation emit noise, which can cause hearing damage. Wear appropriate ear protection at all times.

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.

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.

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. Do not operate the generator set with any doors open.

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.

Automated Machinery: Accidental or remote starting of the generator set can cause severe personal injury or death. The generator set must be off and locked out of service whenever the air inlet, air outlet, or any interior panels are removed. Isolate all auxiliary supplies and use an insulated wrench to disconnect the starting battery cables (negative [-] first).

Fire Extinguishers: 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.

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

Do Not Step on Generator Set: Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel, coolant, or exhaust leaks.

Moving Parts Can Cause Severe Personal Injury or Death

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

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

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

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

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

Alternator Operating Areas – Ejected Debris

Debris ejected during catastrophic failure can cause serious injury or death by impact, severing or stabbing. To prevent injury:

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

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

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

• Do not overload the alternator.

• Do not run an alternator with excessive vibration.

• Do not synchronize parallel alternators outside the specified parameters.

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

Voltages and currents present an electrical shock hazard that can cause severe burns or death. Contact with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC or higher can cause electrical shock and electrical arc flash.

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

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

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

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

• Follow all applicable regional electrical and safety codes.

Guidelines to follow when working on energized electrical systems:

It is the policy of Cummins Inc. to perform all electrical work in a de-energized state. However, employees or suppliers may be permitted to occasionally perform work on energized electrical equipment only when qualified and authorized to do so and when troubleshooting, or if de-energizing the equipment would create a greater risk or make the task impossible and all other alternatives have been exhausted.

In summary:

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

• Understand and assess the risks – use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning.

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

Local electrical codes and regulations may require the installation of a disconnect means for the generator set, either on the generator set or where the generator set conductors enter a facility.

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

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

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

The equipment may have more than one source of electrical energy. Disconnecting one source without disconnecting the others presents a shock hazard. Before starting work, disconnect the equipment, and verify that all sources of electrical energy have been removed.

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

• DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel system.

• 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 because copper will become brittle if continuously vibrated or repeatedly bent.

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

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

Gaseous Fuels: Natural gas is lighter than air, and will tend to gather under covered areas.

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.

Exhaust gases are deadly. Follow these precautions:

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

• Make sure the unit is well ventilated.

Exhaust Precautions:

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

• 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.

• 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.

• 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.

Make sure that the exhaust outlet is not obstructed. Position the exhaust away from flammable materials and make sure that vegetation is removed from the vicinity of the exhaust. To minimize the risk of fire, make sure that the engine is allowed to cool thoroughly before performing maintenance or operation tasks.

Carbon monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas that can be lethal. Engine-driven generator sets produce harmful levels of CO.

Special Risks of CO near the Home:

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.

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.

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.

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.

After determining that a printed circuit board assembly is faulty, replace it. Do not repair it. Attempts to repair a printed circuit board can lead to costly damage to the equipment.

To perform the test procedures in this manual, the following test equipment must be available:

• True RMS (Root Mean Square) meter for accurate measurement of small AC and DC voltages

• Grounding wrist strap to prevent circuit board damage due to electrostatic discharge (ESD)

• Wheatstone bridge or digital ohmmeter

• Load bank

• Megger or insulation resistance meter

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.

The maximum load imbalance allowed is 50% of generator set rating.

Note: Maximum pressure for either fuel under any condition: 3.2 kPa (13 inch water column)

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

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 service provider. Maintenance tasks should only be undertaken by trained and experienced technicians provided by your Cummins service provider.

Once the battery is connected to the generator set and any display button is pressed, the local display shows an “establishing communications” message for approximately 5 seconds. (This may take longer if the signal integrity is poor between the control and display due to a bad wire or Electro-Magnetic Interference [EMI].) Once communication is established, the display shows the HOME screen.

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

The Clock needs to be reset whenever the battery power is lost or disconnected, or the control has entered “sleep” mode. The optional Remote Monitoring System (RMS) uses the generator set’s clock, which must be set accurately for the RMS to function properly.

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

1. From the Main screen, select Menu.

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

3. Use the arrow keys to set the time and date (mm/dd/yyyy).

4. Select the Next key to go to the Time Zone Setup screen. Use the arrow keys to set the correct time zone.

5. Select the Next key to go to the Daylight Savings screen. Use the arrow keys to enable/disable Daylight Savings. If enabling, select the Next key to highlight the Offset field.

6. Use the arrow keys and Next key to set the offset value for Daylight Savings time (e.g., 060 MIN).

7. Select the Next key to go the screen that is used to set up when Daylight Savings should start. Use the arrow keys and Next key to set Month (1 – 12), Week (0 – 5), Day (Sun – Sat) and Hour (12AM – 12PM).

8. Select the Next key to go the screen that is used to set up when Daylight Savings should end. Use the arrow keys and Next key to set Month (1 – 12), Week (0-5), Day (Sun – Sat) and Hour (12AM – 12PM).

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

Exercise settings need to be reset whenever battery power is lost or disconnected, or the control has entered “sleep” mode. If the time and date have not been set, a pop-up will appear that says, “Set Valid Date and Time”. The exercise schedule must be set accurately to be properly configured.

To set up the exercise function:

1. From the Main screen, select Menu.

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

3. Use the arrow keys to enable or disable the Crank Exercise feature. Select the Next key to go to the Exercise Time field.

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

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

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

• Weekly: will exercise the generator set on every occurrence of the selected day

• Bimonthly: will exercise the generator set on the first and third occurrence of the selected day every month

• Monthly: will exercise the generator set on the first occurrence of the selected day every month

• Never: will never exercise the generator set

6. Select the Next key to go to the date and time fields. Use the arrow keys to set the day and time the generator set will be exercised. Select the Next key to highlight the Exercise Now field.

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

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

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

To adjust the brightness and contrast of the display:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Display Setup. Select the Enter key.

3. Use the arrow keys to set brightness and contrast for the display.

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

To retrieve information about the display:

1. From the Main screen, select Menu.

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

The screen will display software information like Gen SW PN, SW Version, Dis SW PN, etc.

To retrieve information from the Event Log:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Event Log. Select the Enter key.

3. Use the arrow keys to navigate through the Event Log.

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

To retrieve information from the Fault Log:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Fault Log. Select the Enter key.

3. Scroll through the fault log using the up and down double-arrows. Each screen provides a brief description of the fault, the fault code number, the engine hours and the time and date of the fault.

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

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

To retrieve system status:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight System Status. Select the Enter key.

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

The system status screen displays information such as Voltage, Battery Voltage, Engine Hours, and Fuel type.

To prevent unexpected starts from remote devices, disable Remote mode and disconnect the connector on the back of the local display wired to any remote mounted displays.

The Remote function can only be activated (that is, enabled) from the local display.

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

a. From any screen, select the Mode key to get to the Mode screen.

b. Use the arrow keys to enable or disable the Remote mode. Select the Next key to go to the next screen.

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

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

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

2. To enable or disable the Standby mode on the REMOTE display:

NOTICE: Remote must be enabled before Standby mode can be changed from the Remote display. If Remote mode is not enabled, Standby will remain disabled and cannot be changed.

a. From any screen, select the Mode key to get to the Mode screen.

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

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

The capability to automatically add or remove specific electrical loads from the generator set requires that load management devices be wired to the generator set load management outputs.

When the generator set is started automatically in Standby mode due to a loss of utility or manually by the operator, the control will energize all four load management outputs, disconnecting the associated loads from AC power. Once the transfer switch transfers to generator set power, the generator set control will evaluate the total load on the generator set versus a set point programmed into the control (80% of rated).

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

• Priority #1: load control 1

• Priority #2: load control 2

• Priority #3: load control 3

• Priority #4: load control 4

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

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

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

1. Verify that the installation was completed correctly.

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

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

4. Although the generator set is shipped from the factory with the proper level of engine oil, check the oil level before it is started.

5. Start and test the system.

6. Operate the generator set following all the instructions and precautions in the operator manual.

Before leaving the site, if the generator set is ready to be placed in service, enable the Remote and Standby modes from the local display.

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

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.

WARNING: Combustible Vapors

Do not operate a generator set where there are or can be combustible vapors. These vapors can be sucked through the air intake system and cause engine acceleration and overspeeding, which can result in a fire, an explosion, personal injury and extensive property damage.

NOTICE: Standby Mode must be enabled for Auto Start to execute.

In normal operation, utility power is provided through the transfer switch to the building loads; the generator set is not running. If utility power is not available (that is, there is a power outage), the following sequence will be executed to connect building load to the generator set, and then reconnect building load back to the utility power when it is available.

1. The generator set starts.

2. After the generator set reaches rated voltage and frequency, the transfer switch transfers the building load to the generator set. The building’s electrical power is now provided by the generator set.

3. When utility power is restored, the sequence to transfer building load to the utility begins.

4. The generator set continues to run and waits for utility power to stabilize.

5. When utility power is stable for 5 minutes, the transfer switch connects the building load back to utility power.

6. The generator set runs an additional 5 minutes to cool down and then shuts off.

7. Normal operation resumes.

NOTICE: Standby Mode must be enabled for standard exercise to execute.

NOTICE: While the generator set is exercising, the building load remains connected to the utility; it is not transferred to the generator set.

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

a. The generator set starts.

b. After the generator set reaches rated speed and voltage, the exercise timer is started.

c. When the defined exercise time has completed, the generator set stops and normal operation resumes.

NOTICE: Standby Mode must be enabled for Crank Exercise to execute.

When Crank Exercise is enabled, the generator set will alternate between crank only exercise and standard (that is, generator set running) exercise sequences.

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

a. The generator set engine starter engages and rotates the engine, but the engine does not start.

b. The generator set engine starter cranks for 8 seconds, rests for 15 seconds, and cranks another 8 seconds if the generator set control has not verified the information it is monitoring. Depending on the outcome of this sequence, either a shutdown fault message is issued or normal standby operation resumes.

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

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

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

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

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

4. After the generator set reaches rated voltage and frequency, the transfer switch transfers the building load to the generator set (unless the circuit breaker on the generator set is “off”). The building’s electrical power is now provided by the generator set.

The following steps will be executed when Manual Stop is selected at the Local display:

1. Press the red STOP button on the local display. The generator set will stop immediately and the building load will be transferred to the utility.

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

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

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

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

“FAULT” SCREEN

If a generator set fault occurs that will stop the generator set, the red FAULT light illuminates and a Fault message appears. The screen shows the Fault Code (FC) number, a brief description of the fault, current engine hours and the time and date of the fault.

Press the BACK button to reset the fault and return to the home screen. The red FAULT light will shut off.

“NEW EVENT” SCREEN

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

Operation Events include: Manual Stop, Standby Enabled/Disabled, Auto Stop, and Exercise Cycle Started/Completed.

Maintenance and Service Events include: Scheduled Maintenance reminders, Low Battery Voltage warnings, and Low Oil Level warnings. When a maintenance or service event occurs, the New Event screen will display and the display’s yellow service light will turn on. Press the BACK button to return to the home screen and turn off the light (if lit).

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. 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
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 must be used in accordance with local guidelines and legislation.

WARNING: Access
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. 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: 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.

To immobilize the generator set:

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. Thoroughly ventilate the generator set before disconnecting any leads.

3. Turn off and disconnect any AC powered devices at the generator set, such as oil heater, battery heater, and battery charger before disconnecting the battery cables.

4. De-energize and lock off any utility power to the generator set.

5. Turn off the fuel supply to the generator set.

6. Disconnect the negative (-) cable from the battery and secure it from contacting the battery terminals to prevent accidental starting or electrical arcing at the battery.

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

The cover of the generator set is designed to latch securely into the “up” position to prevent accidental closure.

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

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

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.

WARNING: Automatic startup of the generator set can cause severe personal injury or death. Make sure the generator set is shut down and disabled.

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

1. Perform sooner if engine performance deteriorates.

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

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

4. Perform more often when operating in dusty conditions.

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

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

7. Clean slip rings with an approved tool, 3M Scotch Bright pads Maroon (Grit Equiv. 360-400) OR 3M Three-M-ite 400 grit cloth.

WARNING: 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: Do NOT check oil while the generator set is operating.

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

To check the engine oil level:

1. Make sure that the generator set has not been running for approximately five minutes.

2. Clean off the area surrounding the dipstick port and prevent debris from entering the engine.

3. Pull out the dipstick and wipe it clean.

4. Reinsert and fully seat the dipstick.

5. Remove the dipstick and check the oil level.

6. Reinsert and fully seat the dipstick.

If the engine oil level check shows excessive or insufficient levels of oil (oil level line above the High mark or below the Low mark), oil must be drained or added.

WARNING: Contact with hot surfaces or hot engines can cause severe burns.

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 Model Specifications section.

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

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

Draining Oil

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

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

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

3. Open the oil drain cap at the end of the hose and the drain valve at the engine to release oil from the engine into the appropriate container.

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

5. When a sufficient amount of oil has been drained from the system, close the drain valve at the engine and the oil drain cap on the hose.

6. Wipe the oil drain cap clean.

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

8. Dispose of the used oil in accordance with local and state regulations.

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

1. Open the generator set’s circuit breaker to prevent the ATS from transferring to generator set source when manually starting.

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

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

4. 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. 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.

d. If applicable, disconnect the oil heater from its AC power source (or turn off power).

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

6. Open the oil drain cap at the end of the hose and the drain valve at the engine to release oil from the engine into the appropriate container.

7. Close the drain valve at the engine and the drain cap on the hose.

8. Wipe the oil drain cap clean.

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

10. Remove the oil filter by turning it counterclockwise.

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

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

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

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

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

16. Add the appropriate amount of oil.

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

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

19. Make sure the generator set breaker is open.

20. Reconnect the cables and battery charger:

a. Reconnect the engine battery cables, positive (+) cable first.

b. Reconnect the battery charger to its AC power source.

21. Reconnect the oil heater AC power or energize its AC circuit.

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

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

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

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

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

27. Restore the original generator set settings.

28. Close the generator set breaker.

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

a. Press the generator set’s red STOP button on the local display to stop the generator set. Allow the generator set to thoroughly cool to the touch.

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

c. Disconnect the negative (–) cable from the battery first and secure it from contacting the battery terminals to prevent accidental starting. Then disconnect the positive cable.

2. Open the hood.

3. Remove the control access panel.

4. Remove the intake air and exhaust panels.

5. Remove the oil filter access panel.

6. Remove the oil cooler bolts and move the cooler out of the way.

7. Remove the starter access panel.

8. Remove the valve covers from both cylinders.

9. Using a socket and extensions attached to the flywheel bolt, rotate the engine clockwise until the intake valve closes on one of the cylinders (that is, there is no rocker arm or valve movement).

10. Rotate the crankshaft another 45–135° clockwise. No movement of the rocker arm should be seen.

11. Check the valve clearance with a feeler gauge. If it is out of specification, adjust the intake valve clearance to the lower specification limit.

12. To adjust the valve clearance:

a. Loosen the locking nut and hold it in place with a spanner wrench.

b. Turn the adjusting nut with a hex wrench to adjust the valve clearance.

c. When the desired valve clearance has been reached, hold the adjusting nut in place and tighten the locking nut to 14–18 Nm (10.3–13.3 ft-lb).

13. Using the socket and extensions attached to the flywheel bolt, rotate the engine clockwise until the exhaust valve closes, and the intake valve begins to open.

14. Check the valve clearance and if it is out of specification, adjust the exhaust valve clearance to the lower specification limit (see step 11).

15. Repeat steps 9 through 14 to adjust the intake and exhaust valves for the remaining cylinder.

16. Assemble the valve cover using a new valve cover gasket. Torque the bolts to 8–12 Nm (71–106 in-lb) following the sequence shown in the manual’s diagram.

17. Install the starter access panel.

18. Install the oil cooler.

19. Install the oil filter access panel.

20. Reconnect the battery cable.

21. Install the intake air and/or exhaust panels.

22. Install the control access panel.

23. Close the hood by lifting the hood latch pin out of the slot in the hood hinge and pushing down on the hood.

24. Restore utility power and generator settings.

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

AIR CLEANER ELEMENT REMOVAL

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

a. Press the generator set’s red STOP button on the local display to stop the generator set. Allow the generator set to thoroughly cool to the touch.

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

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

2. Remove the access cover to get to the air cleaner housing.

3. Wipe away any debris accumulated on the air cleaner housing.

4. Remove the two M6 pan head screws.

5. Remove the top of the air cleaner housing which contains the air cleaner element. Ensure that no debris is allowed to enter the base of the air cleaner housing or the engine intake.

6. Pull up on the fastener end of the housing top and slide it back to release it from the tabs.

7. Remove the dirty cleaner element.

8. Dispose of the dirty cleaner element in accordance with local environmental agency requirements.

AIR CLEANER ELEMENT INSTALLATION

1. Clean the gasket surface on the air cleaner housing base.

2. Place the new air cleaner element in the air cleaner housing top.

3. Push the element into the housing until its gasket is fully seated against the housing top.

4. Place the slots on the top over the tabs on the housing bottom, and rotate the cover to the seated position.

5. Install the two pan head screws into the housing base. Torque to 2.3 – 3.0 ft-lb (3.2 – 4 Nm).

6. Re-install the access panel and tighten the screws. Torque 3.5 – 5.0 ft-lb (5.0 – 6.6 Nm).

7. Reconnect the battery and restore the original generator set settings.

WARNING: Exhaust components become very hot. Allow components to cool completely before performing any maintenance tasks.

WARNING: Inhalation of exhaust gases can result in serious personal injury or death. Be sure deadly exhaust gas is piped outside and away from windows, doors or other inlets to buildings.

With the generator set operating, listen for any unusual noises coming from the exhaust system, focusing on the exhaust manifold, muffler, and exhaust pipe. If detected, allow the unit to cool and immobilize the generator set by disconnecting the battery. Lift the cover, making sure it locks into the upward position, and remove the panels over the alternator. Look for any leaks at all connections, welds, gaskets, and joints. Repair as necessary and reconnect the battery.

WARNING: Ignition of battery gases is a fire and explosion hazard. Do not smoke, or switch the trouble light ON or OFF near a battery. Touch a grounded metal surface first before touching batteries to discharge static electricity. Stop the generator set and disconnect the battery charger before disconnecting battery cables. Using an insulated wrench, disconnect the negative (–) cable first and reconnect it last.

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

2. Check the terminals on the batteries for clean and tight connections. Loose or corroded connections create resistance, which can hinder starting. Clean and reconnect the battery cables if loose, using an insulated wrench.

WARNING: Arcing Hazard
Never lay tools or metal objects across the top of the battery.

WARNING: Electric Shock Hazard
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. Wear full eye protection and protective clothing. If electrolyte contacts the skin, 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.

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.

WARNING: 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.

WARNING: 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.

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.

Over time the slip rings can have a build up of corrosion which needs to be cleaned off in order to have normal operation of the alternator. To clean the slip rings:

1. Press the generator set’s red STOP button on the local display to disable the generator set. The generator set stops immediately and both remote and standby modes are disabled.

2. Locate and remove the brush block access cover.

3. Use a Scotch Brite pad and clean off build up on the slip rings. If necessary, rotate the alternator by hand while cleaning.

NOTICE: Do not use anything other than a Scotch Brite pad as this will cause damage to the slip rings and alternator.

4. Replace the brush block access cover and start the generator set.

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

A complete system test is recommended to verify that the electrical system is working properly. Testing the system once every 200 hours or every 2 years is required.

To initiate a complete system test:

1. Before starting:

• Check the oil level.

• Verify that fuel related components, such as manual valves, outside of the generator set are open.

• See the Checklist section in the installation manual.

2. Place the generator set in Standby mode.

3. Switch the main utility disconnect from the ON to the OFF position.

4. Make sure the following occurs:

a. The generator set starts.

b. After the generator set starts and stabilizes, the load is transferred from the utility to the generator set.

5. Switch the main utility disconnect from the OFF to the ON position.

6. Make sure the following occurs:

a. After approximately 5 minutes, the load is transferred back to the utility.

b. Once the transfer switch is connected to utility power, after approximately 5 minutes, the generator set stops.

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

NOTICE: Once the battery is connected to the generator set and any display button is pressed, the local display shows an “establishing communications” message for approximately 5 seconds. (This may take longer if the signal integrity is poor between the control and display due to a bad wire or Electro-Magnetic Interference [EMI].) Once communication is established, the display shows the HOME screen.

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

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

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

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

4. Connect InPower and update the software.

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

WARNING: When the generator set is in Remote mode, it may start unexpectedly. Because any display configured as “Local” can enable the generator set’s Remote mode, make sure that only the display located at the generator set is configured as “Local”.

To access the HMI Type screen:

1. From the Main screen, select Menu.

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

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

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

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

The display’s Generator Config screen has two generator set parameters (Config and Fuel Type) that must be configured if the control board is replaced or re-configured; failure to do so will result in Fault Code 37. To configure the generator set:

1. From the Main screen, select Menu.

2. Press and hold the Next key on the Menu screen for at least 5 seconds to view the Config Menu.

3. Use the arrow keys to highlight “Config” and click the Enter key. The Generator Config screen appears.

4. The default setting for the Config field is 1. Use the Next key to navigate to the Config field. Use the arrow keys to select the appropriate config option.

5. Use the Next key to navigate to the Fuel Type field. Use the arrow keys to select the fuel type: NG (natural gas; default) or LP (liquid propane).

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

a. Lift top cover.

b. Remove 2 screws on top of the exhaust panel.

c. Remove the exhaust panel.

d. Remove 2 screws securing the fuel selector access cover and remove access cover.

e. Reach through the fuel selection handle access opening and turn the handle counterclockwise until it reaches detent (90° from starting position). The handle should be horizontal for LP, vertical for NG.

f. Reinstall the fuel selector access cover. Torque screws 5–6.6 Nm (44–58 in-lb).

g. Reinstall the exhaust panel. Torque screws 5–6.6 Nm (44–58 in-lb).

h. Close the generator set cover.

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

The display’s Adjustments screen has two generator set parameters that are used to configure the readings on the generator set HMI screen only.

NOTICE: The parameter values on the Adjustments screen are for HMI purposes only. Adjustments to the parameters do not change the physical values seen from the generator set.

1. From the Main screen, select Menu.

2. Press and hold the Next key on the Menu screen for at least 5 seconds to view the Config Menu.

3. Use the arrow keys to highlight “Adjustments” and click the Enter key. The Adjustments screen appears.

4. Use the Next and Previous keys to select the parameter to be changed.

5. Use the arrow keys to adjust the parameter to the appropriate value.

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

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

a. Press the generator set’s red STOP button on the local display to stop the generator set. Allow the generator set to thoroughly cool to the touch.

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

c. Disconnect the negative (-) cable from the battery first and secure it from contacting the battery terminals to prevent accidental starting. Then disconnect the positive cable.

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

3. Remove the control access panel.

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

5. Remove the bolt retaining the control board.

6. Remove and replace the control board.

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

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

9. Enter the serial number and model part number from the generator set nameplate:

a. From the Main screen, select Menu.

b. Press and hold the Next key on the Menu screen for at least five seconds to view the Config Menu.

c. Press the Next key to get to the next page.

d. Highlight “Nameplate Config” and press the Enter key.

e. Manually enter the serial number and model part number from the generator set nameplate.

NOTICE: The model part number must be in the 8-digit “A061_###” part number format.

The menu system is navigated using the NEXT, PREV, ENTER, and arrow buttons on the display. A typical navigation path is as follows:

1. Main Screen: Shows basic status like Battery Voltage and Genset Status. Buttons available are START, LOAD, MENU.

2. System Status Menu: Accessed by pressing MENU from the Main Screen. Options include System Status, Event Log, Fault Log, Clock, and Exercise. Use NEXT and arrow keys to navigate, and ENTER to select.

3. Configuration Menu (Config Menu): From the System Status Menu screen, press and hold the NEXT button for at least 5 seconds. This will bring up the Config Menu with options like Config, Adjustments, and HMI Type.

4. Nameplate Config Menu: By navigating through the Config Menu, you can access the Nameplate Config to view the Genset SN and Model No.

The main components of the fuel system are listed in the table below:

Fuel Pressure Requirements: The minimum pressure refers to supply pressure under rated load (maximum gas flow). See the Model Specifications section for the maximum permissible fuel supply pressure for propane vapor and natural gas.

The generator set leaves the factory set up for natural gas (NG). For operation on liquid propane (LP) vapor, the generator set must be converted by configuring the control for propane and manually changing the fuel valve position.

Part 1: Change the Fuel Type in the Control System

1. From the Main screen, select Menu.

2. Press and hold the Next key on the Menu screen for at least 5 seconds to view the Config Menu.

3. Use the arrow keys to highlight “Config” and click the Enter key. The Generator Config screen appears.

4. Use the Next key to navigate to the Fuel Type field. Use the arrow keys to select the fuel type: NG (natural gas; default) or LP (liquid propane).

NOTICE: Do not change the number in the Config field. The Rating field is not configurable by the user; it will be automatically populated based on the Config and Fuel Type selections.

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

Part 2: Adjust the Manual Fuel Selector to the LP Setting

1. Lift the top cover.

2. Remove 2 screws on top of the exhaust panel.

3. Remove the exhaust panel.

4. Remove 2 screws securing the fuel selector access cover and remove the access cover.

5. Reach through the fuel selection handle access opening and turn the handle counterclockwise until it reaches the detent (90° from the starting position).

NOTICE: The handle should be horizontal for LP, vertical for NG.

6. Reinstall the fuel selector access cover. Torque screws to 5–6.6 Nm (44–58 in-lb).

7. Reinstall the exhaust panel. Torque screws to 5–6.6 Nm (44–58 in-lb).

8. Close the generator set cover.

If the generator set does not start, first determine if the fuel shutoff valve is functioning.

1. Locate the wire pairs marked FS1, FS2 and PT1, PT2 behind the service access panel. Disconnect terminals FS1 from PT1 and FS2 from PT2.

2. Check that battery voltage is being supplied through the generator set harness to the solenoid of the fuel shutoff valve. Use a multi-meter to measure DC voltage between FS1 and FS2 while trying to start the engine. Verify that the voltage is between 10.2 and 13.5 VDC.

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

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

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

3. Check for proper solenoid operation.

a. Apply 12 VDC between PT2 and PT1.

b. Listen for solenoid activation. If no audible indication, repeat the application of 12 VDC to the leads with fingers on the solenoid body. Repeat applying the voltage a few times to make sure the solenoid operates correctly.

c. If the solenoid does not activate, replace the fuel pressure regulator or solenoid in the fuel pressure regulator.

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

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

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

GOVERNOR ACTUATOR REMOVAL

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

2. Open the generator set breaker.

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

4. Disconnect the generator set battery, negative post first, then positive post.

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

6. Remove the control access panel.

7. Disconnect the two actuator leads from the main harness.

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

9. Remove the 2 actuator mounting bolts from the bracket.

10. Remove the governor actuator.

GOVERNOR ACTUATOR INSTALLATION

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

a. Apply Loctite to the male threads of the pivot joint and loosely install the upper jam nut.

b. Bottom out the ball socket on the male threads of the pivot joint.

c. Apply Loctite to the male threads of the actuator and loosely place the lower jam nut onto the actuator arm.

d. Bottom out the pivot joint on the male threads of the actuator arm.

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

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

NOTICE: If replacing the actuator with a new part, install the electrical connectors similar to those on the actuator being replaced on the new part. The new part does not have the electrical connectors installed.

4. Reinstall the clip that holds the socket on the ball.

5. Adjust the linkage so the gap between the wide open throttle stop and throttle shaft bracket is 0.25–0.30 mm (0.01 in) with the actuator in its fully retracted position.

NOTICE: Do not adjust the minimum idle throttle stop screw on the mixer.

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

7. Tighten the jam nuts against the base of the ball socket and the base of the pivot joint.

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

9. Install the control access panel.

10. Connect the generator set battery and reset the display settings, including the exercise schedule.

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

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

13. Close the generator set breaker.

Parts required:

– Cylinder head assembly

– Cylinder head gasket

– Valve cover gasket

Tools required:

– General mechanical tools

Procedure:

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

a. Press the generator set’s red STOP button on the local display to stop the generator set. Allow the generator set to thoroughly cool to the touch.

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

c. Disconnect the negative (-) cable from the battery first and secure it from contacting the battery terminals to prevent accidental starting. Then disconnect the positive cable.

2. Remove the necessary enclosure panels and service access panels (and oil cooler if needed) to access the cylinder head.

3. Remove the engine shield below the valve cover.

4. Remove the four valve cover mounting bolts, valve cover and valve cover gasket.

5. Remove the six cylinder head bolts and the cylinder head. Make sure to retain the two cylinder locating sleeves from each cylinder head.

6. Remove the head gasket. Make sure to safely remove any gasket material left behind on the mating surface of the engine block.

7. Install the locating sleeves and the new head gasket.

8. Install the new cylinder head assembly, tightening the bolts in the specified pattern to 50 Nm (36.9 ft-lb).

9. Inspect each push rod for damage before placing them in the cylinder head. Make sure that they seat against the camshaft.

10. Attach the rocker arm and nut to the stud. Tighten the nut to 8–12 Nm (5.9-8.85 ft-lb).

11. Adjust the valve clearance. Tighten the nuts together to 14–18 Nm (10.3–13.3 lb-ft).

12. Remove any gasket material from the valve cover and assemble new valve cover gasket and valve cover. Tighten the bolts following the specified sequence to 8-12 Nm (5.9–8.85 ft-lb).

13. Re-install the intake and exhaust manifolds, and related parts.

14. Re-install the panels that were removed in step 2.

15. Reconnect the battery by first connecting the positive terminal first, then the negative terminal.

16. Restore power to the AC accessories and restore the generator set settings.

17. If possible, test run the generator set with load.

This is a single-bearing, two-pole, revolving field alternator with brushes and slip rings. Output voltage is regulated by the generator set control. Here are the major components:

1. Remove the brush block cover.

2. Disconnect the field leads from the brush block (F1, F2).

3. Remove the two mounting screws.

4. Withdraw the brush block from the alternator end bell.

5. Inspect the brush block:

a. If either brush is shorter than 11 mm (7/16 inch), binds in the brush block, or is damaged in any way, replace the brush block assembly.

i. When re-installing the brush block, make sure to keep the brushes in the retracted position by using a wire through the hole in the end of the brush block. A new brush block assembly will come with this wire in place.

ii. After bolting the brush block securely in place, remove the wire.

b. If the slip rings have grooves, pits, or other damage, use a Scotch Brite pad or commutator stone to remove light wear or corrosion.

6. Re-install the brush block cover.

NOTICE: Make sure that the brushes are aligned correctly with the slip rings; otherwise, the brushes may break when the generator set is started.

1. Rotor Winding Continuity:

a. Test the rotor for grounded, open and shorted windings using an ohmmeter, testing at the brush block terminals first.

b. If the resistance is high, remove the brush block and test directly on the slip rings.

c. Replace the brush block if a high resistance is due to the brushes.

2. Rotor Ground Resistance Test:

a. Set the ohmmeter to the highest resistance scale, or use a megger.

b. Touch one test probe to the rotor shaft and the other to one of the slip rings.

c. Refer to the table below for resistance values. If test values do not match measurement values, replace the alternator.

3. Rotor Winding Resistance:

a. Connect each meter test lead to a separate slip ring.

b. Refer to the table below for resistance values.

4. Main Winding to Quad Winding:

Test for a short between the main windings and the quad windings. If shorted, replace the alternator.

5. Stator Ground Resistance Test:

a. Set the ohmmeter to the highest resistance scale, or use a megger.

b. Touch one test probe to the stack and, in turn, the other to each stator lead. Refer to the table below for values.

6. Stator Winding Resistance:

Use a meter (Wheatstone bridge) having a precision down to 0.001 Ohms to measure stator winding resistance values as shown in the table.

7. Stator Winding for Grounds:

With an ohmmeter, measure each winding to the stator laminations to check for bad insulation. Refer to the table for values.

Rotor and Stator Resistance Tests

*If a stator or rotor fails the initial test, repeat the test to check the validity of the initial measurement before replacing the stator or the rotor.

Maximum wattage or current is subject to derating based on factors like ambient temperature and elevation. Full rated power is available at 15.5 °C (60 °F) at sea level. The following is an example of applying product derates for a C17N6H model generator.

Derate Calculation Example for C17N6H Model

Calculation Steps:

*This schedule is for the C17N6H model only. See the Model Specifications section for generator set derating guidelines for all models.

*See the special instructions in the Alternator and Engine Removal and Installation section.

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

a. Press the generator set’s red STOP button on the local display to stop the generator set. Allow the generator set to thoroughly cool to the touch.

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

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

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

2. Disconnect the leads going into and out of the circuit breaker. There are two sets of leads:

– One set of two leads from the alternator that is installed in the lugs at the top of the breaker (L1 and L2)

– One set of two leads from the customer wiring that is installed in the lugs at the bottom of the breaker (L1 and L2)

3. Check continuity as follows:

– When the breaker is on (that is, the contacts inside the breaker are closed), the continuity check should show very low resistance between the pair of L1 lugs and the pair of L2 lugs.

– When the breaker is off (that is, the contacts inside the breaker are open), the continuity check between L1 and L2 pairs should show open.

The breaker should be replaced if either of the continuity tests fail.

When the battery voltage falls below approximately 13.2 VDC, the charging current will be constant at 4 Amps. When the battery voltage reaches 13.2 VDC, the charger automatically returns to float mode. As soon as the charging current value falls below 0.3 Amp, the charging indicator will turn off.

There are two LED indicator functions:

– POWER: power supply indicator, illuminated when the charger is connected to AC power.

– CHARGING: charging indicator, illuminated when charging current exceeds 0.3 Amps.

Use the following table for initial troubleshooting:

Detailed Procedure:

1. Remove utility power from the utility-power battery charger.

2. Attach a DC voltmeter to the battery and record the battery voltage while the generator set is not running.

3. Open the generator set’s AC output breaker to prevent the ATS from transferring to generator set power.

4. Manually start the generator set.

5. Record the battery voltage with the generator set running.

6. Determine whether the running voltage is above or below the non-running voltage recorded in step 2.

– If the DC voltage is higher than 14.3 VDC, verify that the supply voltage to the regulator is 50 ±5 VAC. If the supply voltage is correct, replace the voltage regulator.

– If the running voltage is at or below the non-running voltage:

a. Shut off the generator set and verify that the flywheel charger’s 20 Amp in-line fuse is not open. It is located near the engine starter.

b. If the fuse is not blown, attach an ammeter to the red, fused output lead of the flywheel charger voltage regulator.

7. Restart the generator set.

8. Confirm that the charger output is positive but under 9 Amps whenever battery voltage is less than 13.8 ±0.5 VDC.

a. If the charger output is positive and under 9 Amps whenever battery voltage is less than 13.8 ±0.5 VDC, no further action needs to be taken.

b. If there is no output and battery voltage is less than 13.8 ±0.5 VDC, stop the generator set and disconnect the 4-pin plug going to the flywheel regulator.

i. Connect an AC voltmeter across the pins of the plug connected to the yellow wires supplying AC power to the regulator from the flywheel alternator.

ii. Verify 50 ±5 VAC across the yellow wires.

– If 50 ±5 VAC is not available, verify the blue wire of the flywheel alternator is at ground. If it is still not available, replace the flywheel alternator.

– If 50 ±5 VAC is available, replace the voltage regulator.

Compression Test Specifications:

Tools Required:

– General mechanical tools (metric and English socket set, etc.)

– Compression test kit

– LocTite Threadlocker Blue 242 or equal

– Torque wrench

– Valve cover gaskets (2). PN: A050X455

– Feeler gauge set

Compression Test Instructions:

1. Shut off the fuel supply to the generator set.

2. Place the generator set in Manual mode (disable standby and remote).

3. Open the generator set circuit breaker.

4. To test:

– Make sure the fuel supply is shut off to the generator set.

– Disable the ignition system by removing both spark plugs.

– Attach the compression tester to the spark plug hole.

– Crank the engine until a stable reading is achieved (approx. 20-30 seconds).

– Record the compression pressure.

– Check and adjust the valve clearance.

5. Replace the valve covers using new gaskets.

6. Replace all of the other removed components.

7. Open the generator set fuel supply.

8. Test run the generator set for 5 minutes.

9. Close the generator set circuit breaker.

10. Enable Remote if desired.

11. Place the generator set in Standby mode if desired.

NOTICE: The InPower tool cannot be connected to the C13N6H, C17N6H, and C20N6H model HMIs.

To connect to the SAAC control using the InPower service tool:

1. Make sure the control is not in sleep mode. Pressing STOP will wake up the control and disable Standby and Remote modes.

2. Remove the J1 plug from back of the HMI (display).

3. Locate the J5 plug.

4. Connect the InPower harness (A044M377) to J5 and to the computer, using the RS485 to RS232 convertor (A001S296) and brainbox serial-to-USB adaptor (A053T968).

– Both parts, A044M377 and A001S296, are included in kit A001L533.

5. Open InPower and double-click on Auto Connect in the menu.

Logic: The generator set control receives a start signal either with Standby enabled or from a remote device with Remote enabled.

Possible Causes:

– Shorted harness connection

– Faulty ATS signal or relay and “Standby” is enabled

– Remote enabled and start command sent from a remote device (display, web page, phone app)

Diagnosis and Repair:

1. If Remote is enabled, a remote start signal may come from the remote monitoring system or remote display. Discuss this with the customer to ensure this functionality is understood.

2. Disconnect the ATS start signal at customer connection TB6 (Remote Start Input).

3. Measure for continuity to GND of both TB6 and customer wiring.

4. If present, inspect the wiring from the ATS for a short to GND and refer to the appropriate RA series ATS owner manual for diagnosis of the ATS.

5. If there is continuity of TB6 to GND, locate the short to ground in the harness, and repair or replace the harness.

Logic: The generator set control receives a stop signal.

Possible Causes:

– Loss of the Remote Start command

– A remote stop command from a remote monitoring device

– Low battery voltage

Diagnosis and Repair:

1. Check the last fault recorded. If a fault was repaired, continue diagnosis. If not, troubleshoot that fault.

2. A remote stop signal may come from the Remote Monitoring System or remote display. Discuss this with the customer to ensure functionality is understood.

3. Verify that both the battery voltage and condition are acceptable. Minimum voltage for display operation is 8V.

4. Measure battery voltage at the battery while attempting to start. Recharge or replace the battery if the voltage drops below 8 VDC. Test the battery charger.

5. Check electrolyte level and hydrometer reading in maintenance-type batteries. Replace electrolyte or battery if necessary.

6. Measure the ATS start signal circuit for an open circuit at customer connection TB6. This may involve checking for ground at the ATS (TB4-1 for RA series) and at the generator control board (P2-4).

7. Verify that P1 and P2 pin sockets on the control board are fully inserted and check for corrosion. Use a mating pin or gauge to check contact wipers. Clean, repair, or replace as needed.

8. Inspect the condition of P1 and P2 pins on the control board. Clean, repair, or replace the board if pins are damaged or corroded.

9. When reconnecting, ensure P1 and P2 plugs are fully seated.

Logic: The control receives a start command but does not crank.

Possible Causes:

– Low or no battery voltage

– Poor battery connection

– Faulty battery

– Open harness connection

– Faulty control board

– Faulty starter

Diagnosis and Repair:

1. Attempt to replicate the fault.

2. Measure the battery voltage at the battery, at the generator set, and at connector P1. Reconnect, clean, repair, and replace connections as necessary.

3. Measure the battery voltage at the generator set while starting. Recharge or replace the battery if the voltage drops below 8 VDC. Test and service the battery charger.

4. Inspect the starter: Verify B+ at the positive battery terminal of the starter and at the starter solenoid while attempting to crank. If the battery is good, replace the faulty starter.

5. Inspect the condition of the control board P1 and P2 pins. If damaged or corroded, clean, repair, or replace the control board.

6. Reconnect the P1 and P2 connectors, ensuring they are fully seated.

7. Test-run the generator set for start operation.

8. Disconnect the generator set control P1 and P2 connectors.

9. Verify that the P1 and P2 pin sockets are fully inserted and inspect for corrosion. Check contact wipers with a mating pin or gauge. Clean, repair, or replace as needed.

Logic: Continuous ground (greater than or equal to 3 seconds) at the generator set control for oil pressure input. The switch opens the control circuit with pressure.

Possible Causes:

– Low/high oil level

– Faulty oil pressure switch

– Faulty oil pressure relief valve in engine

– Harness is faulty (unintentional ground in circuit)

– Faulty oil pump

Diagnosis and Repair:

1. Check the last fault recorded.

2. Measure the oil level. Add or drain oil if necessary.

3. Disconnect the plug from the oil pressure switch and measure continuity from P1-6 and GND. If there is circuit continuity, find and repair the short to ground in the harness.

4. Verify switch operation:

a. Check for continuity (ground) across the switch when the generator set is not running.

b. Check for open across the switch when the generator set is running.

c. Replace the switch if it is not working correctly.

5. Repair or replace the harness if necessary.

6. Measure oil pressure with a mechanical gauge. If oil pressure is low, replace the engine.

Logic: The control did not sense alternator quad winding frequency after cycle crank (30 seconds of cranking and 15 seconds between each attempt for a total of 3 crank attempts).

Possible Causes:

– Generator set did not start, Fuel supply, Air fuel mixture, Wire connections, Starter, Ignition system, Battery, Battery Connections, Battery heater, Oil viscosity, Iced or corroded brushes or slip rings, Open/shorted quad sense or winding, Failed AVR/field flash circuit, Slow cranking speed.

Diagnosis and Repair:

1. Check the last fault recorded.

2. Verify the external fuel valve is open.

3. Disconnect P1 and P2 connectors and check for proper insertion, corrosion, and contact wiper condition.

4. Inspect P1 and P2 pins on the control board for damage.

5. Verify engine rotation manually. Repair if necessary.

6. Measure DC voltage at the starter during start attempt. Repair wire connections or replace starter/solenoid if needed.

7. Check air filter cleanliness.

8. Check for exhaust system damage.

9. For propane models: ensure tanks are at least half full in cold weather and use HD-5 grade propane.

10. Verify the fuel solenoid valve is open and receiving >10.2V during crank.

11. Check fuel lines for leaks and measure fuel supply pressure.

12. Check governor actuator for free motion.

13. Check ignition system: ensure spark plug leads are installed, inspect leads, check magneto output with a spark tester, check flywheel magnet, and inspect spark plugs for damage and proper gap.

14. Measure field, quadrature, and main winding resistance.

15. Check battery heater and oil heater (if applicable) for proper function.

16. Measure quad voltage during cranking. If below 15 VAC, inspect the excitation system.

Logic: Generator set control configuration does not meet any valid configuration.

Possible Causes:

– Generator set configuration

– Control

Diagnosis & Repair:

1. Check the last fault recorded. If this fault has not been repaired, troubleshoot that fault.

2. Using the display, reset and save the generator set configuration. See the instructions in the “Generator Config” Screen section.

3. If the generator set configuration is correct and the fault will not clear, replace the control.

Logic: Occurs when E-Stop switch is grounded. Once activated, it cannot be cleared unless the switch is opened.

Possible Causes:

1. Activated local E-Stop button

2. Faulty connection or faulty E-Stop switch

Diagnosis and Repair:

1. Activated local E-Stop button

a. Reset the E-Stop:

i. Pull the E-Stop button out.

ii. Press the STOP button on the local display to clear the fault code.

2. Faulty connection or faulty E-Stop switch

a. Verify that the E-Stop button is working properly. The E-Stop button is a closed contact when it is pulled out (not active) and an open contact when pressed (active).

– Check for an open circuit condition in the connection and/or wiring from the E-Stop control input (J1-16 input).

Logic: The temperature at the alternator is too high. The high temperature switch opens between 197 – 209 °F (91.5 – 98.5 °C). An open condition on this circuit triggers the fault.

Possible Causes:

– Wire connections

– Faulty temperature switch

– Faulty generator set or fan drive

– Cooling air flow not adequate

Diagnosis & Solution:

1. Check the last fault recorded.

2. Verify the generator set air inlet and air outlet panels are not obstructed. Verify that there are no foreign objects within the enclosure that limit air flow.

3. Disconnect the generator set control P1 connector.

4. Verify that the P1 pin socket is fully inserted and inspect for corrosion and acceptable contact wiper condition. Clean, repair, or replace as needed.

5. Inspect the condition of the P1 pin on the control board. If damaged or corroded, clean, repair, or replace the control board.

6. Reconnect the harness plug ensuring it is fully seated.

7. Reconnect the P1 connector and test-run the generator set for fault occurrence.

8. Measure the temperature sensor wiring (P1-33 to GND) for continuity to ground. Repair or replace as necessary. If the circuit is open, check the harness and temperature switch for open conditions.

9. Visually inspect the generator set cooling fan for missing or damaged blades. Replace the fan if damaged. The fan is connected to the rotor via a taper joint; verify a secure connection.