Cummins/Onan C500 D6e Generator Set

⚠ Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (–) cable from the battery terminal.

⚠ Improper wiring can cause a fire or electrical hazard.

⚠ Backfeed to utility system can cause electrocution or property damage. Do not connect to any building electrical system except through an approved device.

1. Place the control panel run switch in the OFF position.
2. Turn off or remove AC power from the battery charger.
3. Remove the negative (–) battery cable from the set starting battery.
4. Install the transfer switch, select generator output voltage, connect load cables and connect standard/optional AC equipment.

⚠ Ignition of explosive battery gases can cause severe personal injury or death. Always connect negative (–) battery cable last to prevent arcing.

⚠ Ventilate battery area before working on or near battery.

1. Make sure that the PCC is in the OFF mode before connecting the battery cables.
2. Connect the positive battery cable before connecting the negative battery cable to prevent arcing.
3. Service the batteries as necessary.
4. If an automatic transfer switch is installed without a built-in charge circuit, connect a separate battery charger.

⚠ The coolant heater must not be operated while the cooling system is empty or damage to the heater will occur.

1. Connect the heater to a source of power that will be on during the time the engine is not running.
2. Ensure the supply voltage and circuit current is correct for the heater element rating.

1. Ensure the CT dot is facing toward the generator reconnection terminal block (conventional current flowing into the dot).
2. Route the load lead (U, V or W) through the appropriate CT per the Reconnection Diagram.
3. Connect CT secondary wire marked 1 to pin 1 of the CT.
4. Connect CT secondary wire marked 2/3 to pin 3 for low voltage generator sets.

1. The CT has a dot on one side; the dot must be facing toward the generator reconnection terminal block (conventional current flowing into the dot).
2. A dot is also used to indicate pin 1 of the CT.
3. Route the load lead (U, V or W) through the appropriate CT (refer to Reconnection Diagram).
4. The CTs have dual secondaries (3 pins). CT secondary wire marked 1 is connected to pin 1; wire marked 2/3 is connected to pin 3 for low voltage generator sets.

⚠ Hazardous voltage! Ensure all power is off before performing control wire installation.

⚠ Always run control circuit wiring in separate metal conduit from AC power cables.

Tools: cable ties, flexible conduit

1. Route the control wiring through the bottom of the control housing, keeping DC wiring away from high voltage AC wiring.
2. Use cable ties to keep control wiring away from sharp edges and AC power cables within the control housing.
3. Use 20 gauge stranded copper wire for digital connections less than 305 metres (1000 feet).
4. Use 18 gauge stranded copper wire for digital connections 305 to 610 metres (1000 to 2000 feet).
5. Determine the gauge of stranded copper wire for relay connections according to the devices attached.

⚠ Water or moisture inside a generator increases the possibility of flashing and electrical shock. Do not use a generator which is not dry inside and out.

1. Connect the heater(s) terminals to a source of power that will be on during the time the engine is not running.
2. Be sure the supply voltage and circuit amperage is correct for the heater element rating.

⚠ Bonding and grounding must be done properly. All metallic parts that could become energized under abnormal conditions must be properly grounded.

1. Make sure the generator set is grounded to earth in one location only.
2. On generators without a circuit breaker, ground to the point indicated on the top of the generator.
3. On generator sets with circuit breakers, use the ground lug provided in the circuit breaker box.
4. For a 3-pole ATS, the generator neutral is connected to the ATS and is NOT bonded to ground at the generator.
5. For a 4-pole ATS system, use a grounding electrode conductor and a bonding jumper to connect the generator neutral to ground.

1. Bolt stranded load wires to the appropriate terminals on the generator reconnection terminal block or circuit breaker lugs.
2. Connect terminals marked U, V, W and N to indicate line and neutral connections (U, V, W = L1, L2, L3; N = L0).
3. Balance loads so that current flow from each line terminal (L1, L2 and L3) is about the same.
4. Ensure each line current is within 10 percent of median value and no line current exceeds the nameplate rating.

⚠ The use of unapproved isolators may result in harmful resonances and may void the generator set warranty.

Tools: anchored mounting bolts, flat washer, hexagonal nut, 38mm x 152mm pipe

1. Mount the generator set on a substantial and level base such as a concrete pad; the pad must be non-combustible material.
2. Use 16mm (5/8 inch) anchored mounting bolts to secure the generator bedframe to the base.
3. Secure the generator bedframe to the skid using flat washer and hexagonal nut for each bolt.
4. Insert the 38mm x 152mm (1-1/2 x 6 inch) pipe over the mounting bolts to allow minor adjustment for alignment.

⚠ Do not lift the generator set by attaching to the engine or alternator lifting points.

⚠ Before lifting/transportation of the generator set ensure the fuel tank is empty.

⚠ Never stand underneath a lifted generator set.

Tools: shackles, chains, spreader bars, crane/hoist, ropes

1. Attach the lifting device to the lifting points only, using suitable shackles, chains and spreader bars.
2. Slowly tighten the slings and inspect the lifting attachments before commencing a full lift.
3. Hoist the generator set slowly using the indicated lifting points only.
4. Guide the generator set with ropes at a safe distance to prevent uncontrolled rotation.
5. Move the generator set to the desired location and place in position, bringing the set down slowly.
6. Loosen the slings, unhook and remove the shackles.

⚠ Do not attempt to lift a generator set with an undersized forklift truck.

⚠ Transportation and handling by forklift trucks must only be undertaken by suitably trained and experienced personnel.

Tools: forklift truck

1. Position the arms of the forklift under the frame or pallet, making sure the mainframe is resting on the arms.
2. Lift and handle the equipment slowly.
3. Set down the generator set in its final position slowly.